METHODS AND APPARATUS TO POWER AN EXERCISE MACHINE

• US 20140077494A1
• Filed: 09/13/2013
• Published: 03/20/2014
• Est. Priority Date: 09/14/2012
• Status: Active Grant

• Current Assignee: Life Fitness LLC
• Original Assignee: Brunswick Corporation
• Inventors: Jiang, Ming, Sutkowski, Robert, Wong, John, David, Ferdinand
• Granted Patent: US 9,579,534 B2
• Time in Patent Office: Days
• US Class Current: 290/7
• CPC Class Codes: A63B 21/0053 using alternators or dynamos
• CPC Class Codes: A63B 21/0055 the produced electric power used as a source for other equipment, e.g. for TVs
• CPC Class Codes: A63B 22/0056 the pivoting movement being in a vertical plane, e.g. steppers with a horizontal axis platforms for rocking motion about a horizontal axis A63B22/16
• CPC Class Codes: A63B 22/0605 performing a circular movement, e.g. ergometers
• CPC Class Codes: A63B 22/0664 performing an elliptic movement
• CPC Class Codes: A63B 2220/54 Torque
• CPC Class Codes: A63B 24/0087 Electric or electronic controls for exercising apparatus of groups A63B21/00 - A63B23/00, e.g. controlling load
• CPC Class Codes: A63B 71/0619 Displays, user interfaces and indicating devices, specially adapted for sport equipment, e.g. display mounted on treadmills
• CPC Class Codes: F03G 5/06 other than of endless-walk type
• CPC Class Codes: F03G 5/064 using a bicycle or a bicycle pedal, e.g. pedal generators
• CPC Class Codes: F03G 5/086 using flywheels
• CPC Class Codes: H02P 27/08 with pulse width modulation
• CPC Class Codes: H02P 9/04 Control effected upon non-electric prime mover and dependent upon electric output value of the generator
• CPC Class Codes: H02P 9/48 Arrangements for obtaining a constant output value at varying speed of the generator, e.g. on vehicle H02P9/04 - H02P9/46 take precedence

Abstract

Methods and apparatus to power an exercise machine are disclosed herein. An example method includes measuring a power supply current produced by a user of the exercise machine. A rotations per minute of the exercise machine is measured. A power supply reference current is determined, the power supply reference current based on a user selected wattage and the rotations per minute. A differential power supply current is calculated based on the power supply reference current and a measured current of a power supply of the exercise machine. A power supply duty cycle is calculated based on a previous power supply duty cycle, a time constant, the differential power supply current, and a previous differential power supply current, the power supply duty cycle to control power supplied to a console of the exercise machine. The power supply duty cycle is output to a power output controller.

Claims

1. A method to power an exercise machine, the method comprising:

measuring a power supply current produced by a user of the exercise machine;

measuring a rotations per minute of the exercise machine;

determining a power supply reference current, the power supply reference current based on a user selected wattage and the rotations per minute;

calculating, with a processor, a differential power supply current based on the power supply reference current and a measured current of a power supply of the exercise machine;

calculating, with the processor, a power supply duty cycle based on a previous power supply duty cycle, a time constant, the differential power supply current, and a previous differential power supply current, the power supply duty cycle to control power supplied to a console of the exercise machine; and

outputting the power supply duty cycle to a power output controller.

2. The method as described in claim 1, wherein the time constant is a first time constant, and further comprising:

calculating a torque value based on a measured brake current and the power supply reference current;

calculating a differential torque value based on a reference torque value and the calculated torque value;

calculating a brake current duty cycle based on a previous brake current duty cycle, a second time constant, the torque value, and the differential torque value, the brake current duty cycle to control resistance of a brake of the exercise machine;

outputting the brake current duty cycle to a brake controller of the exercise machine.

3. The method as described in claim 2, wherein the brake current duty cycle is further based on a proportional gain value.

4. The method as described in claim 2, wherein the brake current duty cycle is output as a pulse width modulated signal.

5. The method as described in claim 2, further comprising calculating the reference torque based on the user selected wattage and the rotations per minute of the exercise machine.

6. The method as described in claim 5, wherein the reference torque is further calculated based on a mechanical constant.

7. The method as described in claim 1, further comprising receiving the user selected wattage from the console of the exercise machine.

8. The method as described in claim 1, wherein the power supply duty cycle is output as a pulse width modulated output.

9. The method as described in claim 1, further comprising setting the power supply reference current to zero when the rotations per minute of the exercise machine is less than a rotations per minute threshold.

10. The method as described in claim 1, further comprising setting the power supply reference current to zero when a rectified generator output voltage of the exercise machine is less than a voltage threshold.

11. An exercise machine comprising:

a generator to convert movement of a moveable part of the exercise machine into electric power; and

a controller comprising;

a generator power receiver to measure the power output by the generator, and to calculate a rotations per minute of the moveable part;

a mode controller to calculate a power supply duty cycle based on the power output by the generator, the rotations per minute of the moveable part, and a user selected wattage; and

a power output controller to control power provided to a console of the exercise machine based on the power supply duty cycle.

12. The exercise machine as described in claim 11, further comprising the console.

13. The exercise machine as described in claim 11, further comprising:

a power supply to receive power from a commercial power source, wherein the power output controller comprises a first rectifier and a second rectifier in a wired-OR configuration, the first rectifier coupled to the power supply and the console, the second rectifier coupled to the generator and the console.

14. The exercise machine as described in claim 13, wherein the first rectifier is a diode.

15. The exercise machine as described in claim 13, wherein the first rectifier is a controlled switch.

16. The exercise machine as described in claim 13, wherein the power supply duty cycle is a pulse width modulated signal, and further comprising a converter intermediate the second diode and the generator, the converter to receive the pulse width modulated signal.

17. The exercise machine as described in claim 16, wherein the converter is an isolated flyback converter.

18. The exercise machine as described in claim 16, wherein the converter is a switch.

19. The exercise machine as described in claim 11, wherein the generator includes an electromagnetic brake controlled by a resistive load.

20. The exercise machine as described in claim 11, wherein the generator is loaded by a controlled resistive load.

21. A tangible machine readable storage disc or storage device comprising instructions which, when executed, cause a machine to at least:

measure a power supply current produced by a user of the exercise machine;

measure a rotations per minute of the exercise machine;

determine a power supply reference current, the power supply reference current based on a user selected wattage and the rotations per minute;

calculate, with a processor, a differential power supply current based on the power supply reference current and a measured current of a power supply of the exercise machine;

calculate, with the processor, a power supply duty cycle based on a previous power supply duty cycle, a time constant, the differential power supply current, and a previous differential power supply current, the power supply duty cycle to control power supplied to a console of the exercise machine; and

output the power supply duty cycle to a power output controller.

22. The storage disc or storage device as described in claim 21, wherein the time constant is a first time constant, and further comprising instructions which, when executed, cause the machine to at least:

calculate a torque value based on a measured brake current and the power supply reference current;

calculate a differential torque value based on a reference torque value and the calculated torque value;

calculate a brake current duty cycle based on a previous brake current duty cycle, a second time constant, the torque value, and the differential torque value, the brake current duty cycle to control resistance of a brake of the exercise machine;

output the brake current duty cycle to a brake controller of the exercise machine.

23. The storage disc or storage device as described in claim 22, wherein the brake current duty cycle is further based on a proportional gain value.

24. The storage disc or storage device as described in claim 22, wherein the brake current duty cycle is output as a pulse width modulated signal.

25. The storage disc or storage device as described in claim 22, further comprising instructions which, when executed, cause the machine to at least calculate the reference torque based on the user selected wattage and the rotations per minute of the exercise machine.

26. The storage disc or storage device as described in claim 25, wherein the reference torque is further calculated based on a mechanical constant.

27. The storage disc or storage device as described in claim 21, further comprising instructions which, when executed, cause the machine to at least receive the user selected wattage from the console of the exercise machine.

28. The storage disc or storage device as described in claim 21, wherein the power supply duty cycle is output as a pulse width modulated signal.

29. The storage disc or storage device as described in claim 21, further comprising instructions which, when executed, cause the machine to at least set the power supply reference current to zero when the rotations per minute of the exercise machine is less than a rotations per minute threshold.

30. The storage disc or storage device as described in claim 21, further comprising instructions which, when executed, cause the machine to at least set the power supply reference current to zero when a rectified generator output voltage of the exercise machine is less than a voltage threshold.