Magnetic Torque Simulation for Quiet Adjustable Resistance

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Solution Overview

Problem

Conventional strength training machines using iron weight stacks are space-consuming, laborious to adjust, produce noise, and lack flexibility in setting fitness curves for load resistance, while contact torque transmission structures require high-power motors and non-linear resistance adjustment.

Innovation Solution

A smart torque simulation device employing a dual-rotor non-contact torque transmission structure with a winding wheel, outer and inner flywheels, and a control system to regulate armature current, simulating motion resistance through a dual-rotor non-contact torque transmission mechanism.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If iron weight stack is used as load resistance, then strength training function is provided, but device occupies large space and requires manual adjustment of load resistance

Engineering Contradiction:

Improveload resistance adjustmentVSAvoiddevice space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The patent replaces the mechanical iron weight stack system with an electromagnetic torque simulation system. The torque simulation device uses a motor to generate torque that is transmitted through a belt to the winding wheel, eliminating the need for physical weight stacks and manual adjustment mechanisms, thereby reducing space requirements and improving ease of operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the parameter representation from physical weight (iron weight stack) to electromagnetic torque parameters. The load resistance is controlled by adjusting the motor torque output, which can be precisely regulated through electrical parameters rather than manual mechanical adjustment, enabling continuous and precise resistance control.

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If iron weight stack is pulled up and put down, then load resistance is adjusted, but loud impact noise is produced

Engineering Contradiction:

Improveload resistance adjustmentVSAvoidimpact noise

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the mechanical weight stacking and dropping mechanism with a continuous electromagnetic torque control system. The motor can smoothly adjust torque output without discrete mechanical impacts, eliminating impact noise while maintaining load resistance adjustment capability through continuous electrical control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If contact torque transmission structure is used, then torque is transmitted directly, but larger horsepower motor is required and motion resistance cannot be linearly adjusted

Engineering Contradiction:

Improvemotor horsepowerVSAvoidmotion resistance adjustment

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

The patent introduces a belt as an intermediary element between the motor and the winding wheel. This belt transmission system allows for torque transmission with flexibility and cushioning, enabling the use of a smaller motor while achieving smooth, linear adjustment of motion resistance through electrical control of the motor torque output.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 space-efficient, quiet operation with adjustable motion resistance, allowing precise control of load settings and eliminating the need for high-power motors.

Implementation Method 1

let the winding wheel and the outer flywheel be relatively coupled with a magnetic plate and a magnet

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Implementation Method 2

the armature coil is coupled to the field magnet of the inner flywheel, the armature coil has an electric current regulator

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

the power transmission relationship between the inner flywheel and the outer flywheel is achieved through an epicyclic gear set

Methodology Applied

Scientific EffectEpicyclic gearing: Epicyclic Gearing

Data Source

PatentUS12611566B2Smart torque simulation device

Publication Date: 2026.04.28 CHI HUA FITNESS CO LTD

AI summary

The smart torque simulation device includes: a bracket; a shaft center; a winding wheel which having a winding wheel spinning encoder; an outer flywheel which an outer flywheel spinning encoder, the winding wheel and the outer flywheel are relatively coupled with a magnetic plate and a magnet; an inner flywheel with a field magnet, the inner flywheel has a power transmission relationship with the outer flywheel; a coil set, having a coil fixing frame which has an armature coil, and the armature coil is coupled to the field magnet of the inner flywheel, the armature coil has an electric current regulator; and a control system, receiving a winding wheel spinning data from the winding wheel spinning encoder and receiving an outer flywheel spinning data from the outer flywheel spinning encoder, and then sending an armature electric current control data to the electric current regulator.