Modular Footwear Lacing Engine Assembly for Serviceable Automation
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Solution Overview
Problem
Existing motorized lacing systems for footwear face challenges such as high cost of manufacture, complexity, assembly difficulties, lack of serviceability, and fragile mechanical mechanisms, making them unsuitable for mass production and daily use.
Innovation Solution
A modular footwear platform with interchangeable motorized and non-motorized lacing engines, featuring a mid-sole plate that allows for easy assembly and integration of different lacing engines, along with an actuator apparatus providing tactile and visual feedback, and a robust mechanical design to protect the lacing engine from external impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but manufacturing cost increases
Solution Approach 1:
The lacing system is divided into separate functional modules: a motorized lacing engine housed in a dedicated engine housing, a separate actuator assembly with buttons, and a modular spool mechanism. This segmentation allows each component to be manufactured independently using standard processes and assembled through snap-fit connections, reducing overall manufacturing complexity and cost while maintaining automated functionality.
Solution Approach 2:
The motorized lacing engine is designed as a universal module that can be integrated into different footwear types and configurations. The standardized engine housing and actuator assembly can accommodate various spool arrangements and lacing patterns, allowing the same core mechanism to serve multiple product lines and reduce per-unit manufacturing costs through economies of scale.
2Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but device complexity increases
Solution Approach 1:
The system separates the motorized lacing engine from the actuator controls, with each housed in distinct modular units. This segmentation simplifies the overall system architecture by creating clear functional boundaries, making the system easier to understand, manufacture, and service despite maintaining automated tightening capability.
Solution Approach 2:
A flexible coupling mechanism serves as an intermediary between the actuator assembly and the lacing engine, transmitting mechanical forces while accommodating misalignments and reducing the precision requirements of individual components. This intermediary element simplifies the connection interface and reduces overall system complexity.
3Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but assembly difficulty increases
Solution Approach 1:
The lacing system is divided into pre-assembled modules (engine housing with spool, actuator assembly with buttons) that can be manufactured separately and then quickly integrated into the footwear. This segmentation enables parallel manufacturing processes and simplifies final assembly, reducing overall assembly difficulty despite the automated functionality.
Solution Approach 2:
The actuator assembly is designed to be pre-integrated with the button interfaces and control mechanisms, combining multiple functions into a single unit that attaches to the footwear as one piece. This merging of components reduces the number of separate assembly steps and simplifies the integration process into the final footwear product.
4Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but serviceability decreases
Solution Approach 1:
The motorized lacing engine is housed in a separate, removable engine housing that can be independently accessed and serviced. This segmentation allows the motorized components to be replaced or repaired without affecting the entire footwear, significantly improving serviceability while maintaining automated tightening functionality.
Solution Approach 2:
The actuator assembly is designed as a separate, removable unit that can be detached from the footwear and replaced independently. This extraction of the control mechanism from the main structure allows for easy servicing of the automated tightening system without requiring disassembly of the entire footwear or replacement of all components.
5Extent of automation
If motorized lacing systems are implemented in footwear, then automated tightening function is achieved, but mechanical fragility increases
Solution Approach 1:
The spool mechanism is pre-loaded with tensioned lacing strings and positioned within a protective engine housing that cushions against external impacts. This prior cushioning of the mechanical components protects the fragile motorized elements from damage during normal footwear use, maintaining reliability while enabling automated tightening.
Solution Approach 2:
The engine housing and actuator assembly are designed with flexible mounting features and protective coverings that absorb external forces and protect the internal motorized components from impact damage. This protective encapsulation reduces mechanical fragility while maintaining the automated tightening function.
Data Source
AI summary
Systems and apparatus related to an automated footwear platform including an actuator assembly for controlling a footwear lacing apparatus are discussed. In an example, an actuator assembly can include an actuator frame with a plurality of integrated actuators. The actuator frame is adapted to interconnect elements of the actuator assembly, the actuator frame including a width, a length, and a thickness where the width and length form an exterior surface and an interior surface separated by the thickness. The plurality of actuators are integrated into the actuator frame, each actuator of the plurality of actuators including an actuator head extending from the exterior surface and a button interface extending from the backside of the actuator head through the interior surface.