Rotary Drum Optical Encoder for Compact Autolacing Footwear Motors
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Solution Overview
Problem
Conventional optical encoders used in motorized lacing systems for footwear are fragile and have a high stack-up, which can compromise the performance and robustness of athletic footwear, and their manufacturing precision can lead to reliability issues.
Innovation Solution
A three-dimensional optical encoder based on a rotary drum design is developed, which is more compact, robust, and easier to manufacture, featuring a cylindrical shape with segments on its exterior or interior surface, allowing for greater variance in manufacturing processes and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional planar optical encoders are used, then manufacturing precision can be improved, but the encoder becomes fragile and has high stack-up
Solution Approach 1:
The patent transitions from a conventional two-dimensional planar encoder disk to a three-dimensional drum-shaped encoder. The drum configuration with segments arranged on its surface provides inherent structural strength while reducing the stack-up height. This dimensional change allows the encoder to maintain manufacturing precision while significantly improving reliability and reducing fragility.
Solution Approach 2:
The patent employs a drum-shaped (cylindrical) encoder instead of a flat planar disk. The curved surface of the drum provides structural rigidity and reduces the encoder's susceptibility to damage. The cylindrical geometry naturally reduces the stack-up height while maintaining the necessary optical path for precise manufacturing and measurement.
2Measurement precision
If conventional planar optical encoders are used, then measurement accuracy can be maintained, but the stack-up height increases
Solution Approach 1:
By transitioning to a three-dimensional drum configuration, the patent redistributes the encoder segments in three-dimensional space rather than confining them to a flat plane. This allows the optical sensing path to be arranged more compactly, reducing the overall stack-up height while preserving the optical geometry necessary for accurate rotational tracking measurements.
3Measurement precision
If conventional optical encoders are used, then rotational tracking can be achieved, but the device complexity and fragility increase
Solution Approach 1:
The drum-shaped encoder provides a structurally simpler and more robust configuration compared to planar encoders. The cylindrical form factor naturally resists deformation and damage, reducing the need for complex protective structures. This geometric simplification maintains rotational tracking capability while reducing overall device complexity and fragility.
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 three-dimensional optical encoder enhances the reliability and robustness of motorized lacing systems, providing accurate rotational tracking while being more cost-effective and less prone to manufacturing errors, thus improving the performance of athletic footwear.
Implementation Method 1
an optical encoder including a two-dimensional disk... an optical range... first and second plurality of segments
Implementation Method 2
first plurality of segments... second plurality of segments... optical sensor positioned... within an optical range
Data Source
AI summary
An article of footwear and related method includes a midsole, an upper secured with respect to the midsole, and a lace extending through the upper. A motorized lacing system positioned within the midsole, configured to engage with the lace to increase and decrease tension on the lace. The motorized lacing system includes a motor, including a motor shaft, a spool, coupled to the motor shaft, configured to spool and unspool the lace based on the turning of the motor shaft, a processor circuit, and an optical encoder. The optical encoder comprises a three-dimensional encoder defining a major axis and having a surface having a first plurality of segments positioned between a second plurality of segments, and an optical sensor, positioned within optical range of the cylindrical encoder, configured to output a signal to the processor circuit indicative of a detected one of a first and second plurality of segments.