Modular Footwear Lacing Engine for Low-Complexity Auto-Tightening
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Solution Overview
Problem
Existing motorized lacing systems for footwear face challenges such as high cost, complexity, and poor serviceability, as well as the need to balance performance with comfort, while previous designs have not provided a suitable mass production platform.
Innovation Solution
A modular footwear platform with interchangeable motorized and non-motorized lacing engines, incorporating unique design elements like a mid-sole plate that allows for late assembly and integration of various lacing engines, including foot presence sensing and load cell-based tension control, to enable efficient and adaptable automated lacing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If motorized lacing systems are implemented in footwear, then automated lace tightening performance is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The lacing system is divided into separate functional modules: a lacing engine housed in a lacing engine housing, a motor assembly, a spool assembly, and a control system. This modular segmentation allows each component to be optimized independently and simplifies manufacturing and assembly processes while maintaining automated functionality.
Solution Approach 2:
The lacing engine is designed as a universal component that can be integrated into multiple types of footwear (athletic shoes, boots, medical footwear) through standardized mounting interfaces on the mid-sole plate. This multi-functionality reduces development costs and enables mass production of the core lacing mechanism across different footwear products.
2Extent of automation
If motorized lacing systems are implemented in footwear, then automated lace tightening performance is improved, but manufacturing cost increases
Solution Approach 1:
The lacing engine is pre-assembled and tested as a complete functional unit before integration into the footwear. This preliminary assembly allows for standardized manufacturing processes, quality control, and easier replacement if needed, ultimately reducing overall manufacturing complexity and cost.
Solution Approach 2:
The system includes a quick-release mechanism that allows the lacing engine to be easily removed and replaced by the end user without specialized tools or services. This self-service capability reduces maintenance costs and extends the product lifecycle.
3Extent of automation
If motorized lacing systems are implemented in footwear, then automated lace tightening performance is improved, but serviceability deteriorates
Solution Approach 1:
The lacing system uses a modular architecture where the lacing engine is a separate, replaceable component housed in its own housing. This segmentation isolates the complex motorized mechanisms from the rest of the footwear, making it easy to service by simply replacing the entire lacing engine module rather than repairing individual internal components.
Solution Approach 2:
A quick-release mechanism is provided that enables end users to easily remove and replace the lacing engine themselves without requiring specialized service centers or tools, dramatically improving serviceability.
4Adaptability or versatility
If interchangeable lacing engines are provided for different footwear types, then adaptability is improved, but device complexity increases
Solution Approach 1:
The lacing engine is designed with universal mounting features that allow it to be installed in various footwear types (athletic shoes, boots, medical footwear) using standardized interfaces on the mid-sole plate. The same basic lacing engine unit serves multiple footwear applications, reducing overall system complexity despite the variety of uses.
Solution Approach 2:
The system allows dynamic configuration where different lacing engines can be swapped into the same footwear platform depending on the application requirements, enabling adaptability without requiring multiple specialized designs.
Data Source
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AI summary
Lacing engine systems, apparatus, and methods of operation are discussed. In an example, a lacing engine apparatus can include a housing, a drivetrain, and a lace take-up mechanism for retracting a length of lace cable upon activation. The drivetrain can include various reduction gears to reduce rotational speed out of the motor and power the lace take-up mechanism. The lace take-up mechanism can include structures such as a double-yoke, a radial pulley including an outer rotating disc and an inner stationary disc, a variable take-up spool, or a zip-strip mechanism.