High Torque Reluctance Brake for Fitness Equipment
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Solution Overview
Problem
Existing fitness equipment with flywheels and magnetic resistance mechanisms lack automatic adjustment capabilities, are inefficient in load management, and are costly to manufacture, making them unsuitable for small or low-control function applications.
Innovation Solution
A high torque reluctance brake device with a control circuit that adjusts current to magnetic resistance mechanisms to provide variable resistance, incorporating a support frame, external rotor, magnetic resistance mechanisms, and a control circuit unit, allowing for automatic torque adjustment and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment device is used to change gap between rotor and stator, then load resistance can be adjusted, but automatic adjustment capability is lacking
Solution Approach 1:
The patent replaces the manual mechanical adjustment device with an automatic control system that uses sensors to detect flywheel speed and a control unit to adjust the magnetic resistance automatically. The mechanical gap adjustment mechanism is substituted with an electromagnetic control system that automatically regulates the magnetic field strength based on real-time speed feedback, achieving automatic load adjustment without manual intervention.
Solution Approach 2:
The patent implements a feedback control mechanism where sensors continuously monitor the flywheel rotation speed and transmit this information to the control unit. The control unit processes the speed data and automatically adjusts the magnetic resistance accordingly, creating a closed-loop feedback system that enables automatic adjustment of load resistance based on actual operating conditions.
2Ease of operation
If permanent magnets and armatures are used to generate current for control and brake load, then excellent sports effects are achieved, but output power is limited by generator speed and magnetic resistance
Solution Approach 1:
The patent extracts the power generation function from the magnetic resistance system. Instead of using permanent magnets and armatures to generate current for both control and braking, the invention separates these functions: the magnetic resistance mechanism solely provides braking force, while a dedicated transmission system transfers power to the flywheel, eliminating the speed limitation imposed by generator output power.
Solution Approach 2:
The patent replaces the electromagnetic generation system (permanent magnets and armatures) with a direct mechanical transmission system. The flywheel is driven directly by the user's input through a transmission mechanism, eliminating the need for electromagnetic conversion and removing the bottleneck of generator speed limitations, thereby enabling higher output power while maintaining excellent sports effects.
3Reliability
If permanent magnets and armatures with eddy current mechanism are used, then magnetic resistance is achieved, but mechanism complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the complex permanent magnet and armature assembly from the system. The invention retains only the essential magnetic resistance components (magnetic coil, brake field core, and magnetic ring) while removing the power-generating electromagnetic mechanism, thereby significantly reducing device complexity and manufacturing cost while maintaining reliable magnetic resistance functionality.
Solution Approach 2:
The patent replaces expensive permanent magnets and complex armature structures with simpler, more cost-effective electromagnetic components. By using magnetic coils that can be easily manufactured and replaced, the system achieves the same magnetic resistance effect with lower manufacturing costs and reduced structural complexity, making the device more suitable for small or less control function fitness equipment.
4Ease of operation
If magnetic resistance mechanism is used, then non-contact resistance is provided, but manufacturing cost and complexity remain high for small equipment
Solution Approach 1:
The patent employs cost-effective electromagnetic components instead of expensive permanent magnets and complex mechanical structures. The magnetic coil and brake field core can be manufactured using standard electromagnetic fabrication techniques, significantly reducing manufacturing costs while maintaining the non-contact resistance characteristic. This makes the magnetic resistance mechanism economically viable for small or less control function fitness equipment.
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
The device achieves efficient exercise load management with automatic resistance adjustment, reduced manufacturing costs, and increased exercise variability and comfort through the use of a non-contact resistance mechanism with high magnetic flux density and adjustable resistance curves.
Implementation Method 1
the current of the magnetic coil will generate a magnetic field on the brake field core through the principle of electromagnetic induction
Implementation Method 2
since the external rotor is rotating, the closed magnetic circuit will be destroyed, according to Lenz's law, when a stable magnetic circuit is destroyed by external force, a reverse resistance of the same magnitude will be produced
Implementation Method 3
the magnetic ring has high magnetic flux density and arranged closely on the outer periphery of an outer ring body of the flywheel
Implementation Method 4
use armatures as stators to make stator coils generate current to be the power that provided for the control and the brake load; this kind of structure can achieve excellent sports effects
Data Source
AI summary
A high torque reluctance brake device for fitness equipment, comprising: an external rotor including a flywheel and an outer ring body; at least two magnetic resistance mechanisms, each of them has a brake field core, a magnetic coil; a support frame for arranging magnetic resistance mechanisms to form an angle larger than 30 degree and to make between the outer periphery of the brake field core and the outer ring body has a gap; the control circuit unit transmits suitable current to the magnetic coil, then between the brake field core and the magnetic ring produced a eddy current magnetic resistance and forms a reverse resistance to the external rotor. By choosing different resistance setting can increase the variability of exercise and improve the comfort of exercise.