Exercise Machine Combining a Physical Weight Resistance Source and an Electromechanical Resistance Source

The present application generally relates to an exercise machine. The exercise machine comprises a body, a physical weight, an electromechanical resistance module, a pulley system attached to the body and a user interface. The physical weight provides a first resistance source for a first cable, while the electromechanical resistance module provides a second resistance source for a second cable. The pulley system is configured to integrate simultaneously a resistance from the first and second resistance sources into one single output resistance by guiding the first cable and second cable to an adapter to which the first cable and the second cable are attached. The user interface is connected to the adapter and serves to apply a force against the single output resistance.

An exercise machine is a mechanical device designed to support and optimize physical exercises. These machines are commonly used in gyms, rehabilitation centers, and can also be used in private homes to train various muscle groups, improve physical fitness, and achieve specific health goals. There are different types of exercise machines, such as cardio machines that enhances cardiovascular fitness, strength machines that increases muscle strength and mass, and flexibility and stretching machines that improves body flexibility and mobility. Multifunctional machines combine various functions to provide comprehensive training.

Fitness strength machines with weight stacks, also known as selectorized machines, are a common type of exercise machines. These machines typically feature weight stacks ranging from 45 kg to 200 kg, often segmented into 5 kg or 10-pound increments. The weight blocks, often referred to as “Iron Weights”, are connected to a system of cables and pulleys, providing the necessary resistance for a variety of cable-based exercises. These machines are the industry standard in both commercial and home gym environments.

Examples of exercises that can be performed on selectorized machines include lat-pulldowns, chest flyes, seated rowing, shoulder presses, and leg curls. Users can adjust the weight resistance by moving a pin between different weight blocks, allowing for customization of the workout intensity.

However, this adjustment process can be inconvenient as each adjustment requires the user to interrupt the exercise and move away from the training position to change the weight by moving the pin. In addition, conventional machines are not equipped with sensors that focus on analyzing and recording combined weights moved by the first and second resistance sources.

There are already solutions of exercise machines on the market that use electrical motors, flywheels, or magnetic brake systems to provide resistance instead of physical iron weights. These solutions rely on one (non-iron weight) resistance source to provide variable resistance to the user.

However, a disadvantage of these electromechanical resistance systems is, by fully cancelling the iron weights, the loss of haptic feedback that users experience with traditional physical weights. When moving physical weights, users feel the inertia, mass, and gravity of the iron weights, which enhances neuromuscular coordination as they control the weight throughout the exercise. Additionally, there is a psychological and motivational effect associated with visually moving physical weights. Experience shows that it is more positive for an athlete's psyche to move real weights.

US20200254309 A1 and U.S. Pat. No. 7,163,488 B2 each relate to an exercise machine comprising a barbell connected to two cables. The two cables are attached to an electromechanical resistance system that can be adjusted to either assist or resist the lifting of the barbell.

Although the two machines disclosed in the documents combine physical weights with an electromechanical resistance system, they are specifically designed for barbell use with free weights. Consequently, the range of exercises that can be performed with this resistance combination is limited.

The object of the invention was therefore to eliminate the disadvantages of the prior art and to provide an exercise machine that offers a diverse range of exercises without limitations to a barbell-based training, enables an easy weight adjustment for different training regimens, and provides realistic haptic feedback.

The object of the invention is solved by the features of the independent claims. Advantageous embodiments of the invention are described in the dependent claims.

In a first aspect, the application relates to an exercise machine comprising a body, a physical weight, an electromechanical resistance module, a pulley system attached to the body, and a user interface. The physical weight provides a first resistance source for a first cable, while the electromechanical resistance module provides simultaneously a second resistance source for a second cable. The pulley system is configured to integrate simultaneously a resistance from the first and second resistance sources into a single output resistance by guiding the first cable and second cable to an adapter to which the first cable and the second cable are attached. The user interface is connected to the adapter and serves to apply a force against the single output resistance as well as preferably the possibility to adjust the second resistance source.

The integration of a physical weight and an electromechanical resistance module into a single exercise machine offers a versatile workout experience, allowing users to benefit from the tactile feedback of traditional weights as well as the dynamic, software adjustable and precise control of electronic resistance. Physical weights offer high haptic feedback, allowing users to feel inertia, mass, and visually see the movement of the iron weights, which can improve neuromuscular coordination and motivation. In contrast, a fully electrical system would lack this benefit. This invention preserves the tactile and visual feedback of physical weights, while incorporating the advantages of electronic or electromechanical resistance.

The preferred exercise machine enables non-linear force distribution throughout an exercise set without adjusting the physical weight of the iron weight stacks. Users can engage with conventional iron weights while the electromechanical resistance module dynamically ads, increases or decreases resistance within a workout set or even withing a single repetition. This enables a dynamic muscle tension curve, which is widely recognized by scientists as optimal for developing muscle strength.

In addition, the preferred exercise machine can be used for any conventional exercise typically performed with traditional weights. This includes, but is not limited to, the bench press, squat, and deadlift (the three main powerlifting movements), as well as the incline bench press, shoulder press, bent-over row, and lat-pulldown. The preferred exercise machine is also adaptable to various forms and shapes of strength machines. The primary differences lie in the shape of the electromechanical resistance module, the positions of the physical iron weight stacks, and the cable routings of both resistance sources. However, the main principle of combining simultaneously physical weights and an electromechanical resistance module into a Hybrid System remains consistent across different machines.

The pulley system's ability to simultaneously combine resistances from two different sources into a single output enables seamless transition between resistance types, facilitating complex workout routines without the need for manual adjustment of iron weights or settings. The user interface connected to the adapter provides a direct method for the user to engage with the exercise machine by preferably using only one finger (thumb), ensuring that the force applied is effectively resisted by the combined output, thus offering a consistent and measurable training stimulus.

A physical weight in the context of the application refers preferably to a solid, tangible object used to provide resistance during workouts. Typically made of materials like iron, steel or plastic, these weights can also comprise other forms like water tanks or similar objects. They generate resistance through their mass and gravity, requiring users to physically move and control them.

Additionally, a cable refers to a strong, flexible wire or rope used to transmit force and provide resistance during workouts. These cables are typically made of durable materials like steel or high-tensile synthetic fibers, designed to withstand significant tension while connecting various components of exercise machines, allowing for smooth and controlled movement.

Preferably, a pulley system in this application refers to a mechanical arrangement of wheels and cables designed to guide and distribute resistance during workouts. This pulley system typically consists of multiple pulleys and cables that work together to redirect force, allowing for smooth and controlled movements.

A pulley is preferably a wheel mounted on an axle or shaft, designed to facilitate the movement and change the direction of a cable, rope or belt. It features preferably a groove or channel that keeps the cable securely in place. Typically, it includes bearings to ensure smooth operation and is constructed from durable materials such as metal or high-strength plastic. The pulley is usually mounted on robust brackets that attach to a machine. Some pulleys have an adjustment mechanism to alter the height or angle, and include safety features such as guards to prevent cable slippage and protect users. The wheel and groove have a smooth finish to minimize wear on the cable, and the entire assembly is preferably rated for a specific load capacity to ensure safe and effective operation.

In a preferred embodiment the pulley system comprises at least a first pulley and a second pulley, wherein the first pulley guides the first cable, and the second pulley guides the second cable in such way that the first cable and the second cable are oriented parallel to each other. The arrangement of the first and second pulleys to guide the cables parallel to each other ensures a balanced distribution of resistance. This allows the adapter, to which both cables are attached, to be positioned in such a way that any force applied to the adapter is evenly distributed between the two cables.

Alternatively, the pulley system may comprise at least one pulley. If a single pulley is used, it can be designed to have two parallelly aligned grooves or channels for receiving and guiding the first cable and second cable, respectively. It is to be understood that in such case the cables must already be aligned parallel before engaging with the pulley so that they can be received in the parallel channels or grooves.

Preferably, an adapter in the context of the application refers to a device or component that connects and integrates multiple resistance sources into a single output for use during workouts. This adapter joins cables from different resistance mechanisms, such as physical weights and electromechanical modules, ensuring they work together seamlessly. Examples include junction blocks that merge cables from different pulleys or connectors that unify the output from various resistance modules.

In a preferred embodiment, the first cable and the second cable are continuously attached to the adapter via a double cable coupling. The continuous attachment of both cables to the adapter via a double cable coupling means preferably that the first and second cables are permanently or uninterruptedly connected to the adapter. This ensures a reliable and secure connection, reducing the likelihood of cable slippage or detachment during intense workouts. The double cable coupling allows for equal distribution of force from the adapter to both cables, which can enhance the stability and consistency of resistance experienced by the user. The double cable coupling also eliminates the necessity to manually couple or decouple one of both resistance sources or the obligation to switch between both weight sources by manually attaching snap or spring safety hooks. This continues connection of both resistance sources increases safety and convenience.

A double cable coupling may be designed by incorporating a robust and precisely engineered housing that securely holds both cables in place. This housing could be constructed from high-strength materials such as reinforced steel or composite polymers to withstand the substantial forces exerted during use. The coupling mechanism may feature individual slots or channels for each cable, ensuring they remain parallel and evenly tensioned. Additionally, the design might include locking mechanisms, such as set screws or clamping plates, to further prevent any movement or loosening of the cables.

By having the first cable and the second cable continuously attached to the adapter, the electromechanical resistance module remains in an “always on” mode. This means that the electromechanical resistance must always be supplied with power and remain continuously activated to retract the second cable after it has been extended, even when the electromechanical resistance is not applying any resistance during an exercise. The preferred exercise machine is preferably specially designed so that both cables can always be pulled in parallel by the user. If the user chooses mode of pulling only physical weight, the electromechanical module provides almost zero resistance, just enough to pull the cable in.

In this regard, there is no need for the user to switch between resistance sources. The user can start a workout with physical weights and switch to a hybrid resistance workout by using a simple voice command or by pressing a control element, preferably by using just one finger, such as a button or rotating adjustment rings on the user interface. The electromechanical resistance module is preferably always connected to grid power for on-demand power and can be connected to the user's smartphone via Bluetooth or Wi-Fi.

To ensure continuous operation, a power source is provided to supply voltage to the electromechanical resistance. This can be achieved through various means. The proposed exercise machine may include a battery and/or a solar panel, or the electromechanical resistance module may have a connection that allows it to be plugged into the power grid.

Preferably, the first cable and the second cable may be attached to the adapter in such way that the adapter can pull the first cable and the second cable parallel to each other, when force is applied to the adapter. The force applied to the adapter is transmitted through the user interface, which is connected to the adapter. For example, when the user pulls the user interface, the force is directly applied to the adapter. The attachment of the cables to the adapter in a manner that allows parallel pulling action ensures a direct and efficient transfer of force from the user to the resistance sources, maximizing the effectiveness of each exercise performed. The parallel pulling ensures proper alignment adapter of the adapter.

The adapter may comprise a force application point for applying a force against the single output resistance, wherein the force application point is located centrally between the parallel-aligned first and second cables, and wherein the user interface is connected to the force application point. The centrally located force application point ensures balanced force distribution. By connecting the user interface directly to the force application point, the user can have improved control and feedback during exercise, enhancing the effectiveness of the workout.

Furthermore, the adapter may comprise two sleeves which respectively receive the first and second cables, wherein the first and second cables, which are guided in parallel, have a maximum distance from one another which lies in a range between 5 mm-200 mm, preferably a distance which lies in a range between 10 mm-100 mm, in particular a distance which lies in a range between 30 mm-80 mm. The specified range for the maximum distance between the parallel-aligned cables ensures consistent resistance and smooth operation, which can contribute to a more effective and comfortable workout experience. The close proximity of the cables ensures that the adapter remains stable and straight during exercises by the user, even when the resistance sources are significantly different, for instance when no or minimal resistance is applied by the electromechanical module while a high resistance is generated by a physical weight. The inclusion of two sleeves for the cables provides a secure and stable guide for the cables, reducing wear and tear and extending the lifespan of the machine.

In a further preferred embodiment the pulley system comprises four pulleys, wherein a first pulley and a third pulley guide the first cable and a second pulley and a fourth pulley guide the second cable, wherein the first pulley and the second pulley are arranged on a first axis, wherein the third pulley and the fourth pulley are arranged on a second axis, the first axis and the second axis being arranged parallel to each other. The arrangement of four pulleys with the first and third guiding the first cable, and the second and fourth guiding the second cable, allows for a more fluid and natural movement of the cables. By arranging the first and second pulleys on a first axis and the third and fourth pulleys on a second axis, parallel to each other, the machine can provide a consistent and predictable path for the cables, which can improve the user's coordination and reduce the risk of cable entanglement or snagging.

The first axis and the second axis may have a different distance in respect to an attachment surface of the body which is parallel aligned to the first axis and the second axis. Having the first and second axes at different distances from the attachment surface allows for better execution of exercises, as the cables are guided more effectively.

In the context of this application, the attachment surface of the body is a vertically oriented flat surface. It can be moved and fixed along a vertical axis, allowing the height of the pulleys and adapter to be adjusted. This height adjustability allows for performing a variety of exercises, accommodating different user heights, and enhancing the versatility and effectiveness of the workout.

Preferably, an electromechanical resistance module refers to a device that provides adjustable resistance during workouts using electrical and mechanical components. This module can precisely control the level of resistance through electronic means, offering dynamic and customizable workout experiences. Examples include motorized systems or flywheels that use electromagnetic braking to adjust resistance.

In a preferred embodiment the electromechanical resistance module comprises an electric motor with a winch on which the second cable can be wound and unwound. The integration of an electric motor with a winch for winding and unwinding the second cable enhances the precision and reliability of the resistance adjustments, allowing for smooth transitions and consistent resistance levels during operation. The use of an electric motor provides the advantage of automated control over the resistance levels, which can be programmatically adjusted to suit various exercise regimes, thereby offering a tailored workout experience to the user. The winch mechanism allows for compact storage of the second cable when not in use. The electric motor can preferably be a servo motor, a DC motor, and/or a brushless DC motor, ensuring high accuracy and control over the cable movements, allowing for precise adjustments and maintaining consistent tension throughout the exercise.

Furthermore, it is possible for the electric motor to be directly connected to the winch. Alternatively, a gearbox may be interposed between the electric motor and the winch, providing additional mechanical advantage and control over the cable movements.

In a preferred embodiment, the electromechanical resistance module comprises more than one electric motor and more than one winch each connected to an electric motor. This allows for multiple output resistances to be generated in an exercise machine, each combining electromechanical resistance with physical weight resistance. Additionally, an output resistance can be generated that is exclusively based on electromechanical resistance, without the combination with physical weight.

The electromechanical resistance module can, for example, house three electric servo motors, each with a power range between 500 W and 1000 W, along with a servo driver, a controller board, ground connection cables, and Bluetooth communication chips. Other configurations are also possible, where an electric servo motor with a power range of 50 W to 4000 W is used, or within a range of 250 W to 1200 W. The servo motors are not limited to these ranges.

In a further preferred embodiment the electromechanical resistance module comprises a housing which serves as a structural component of the body. The integration of the housing into the machine's body optimizes space usage, leading to a more compact and efficient design that can be advantageous in environments where space is at a premium. Using the housing as a structural element can potentially lower the manufacturing costs and complexity of the machine by reducing the number of separate components required, thus simplifying assembly and maintenance.

The electromechanical resistance module can preferably be mounted overhead in a fitness machine. Its compact design can reduce the overall depth of a power rack, making it more space efficient. This enables the development of more compact exercise machines, suitable for smaller workout areas and home gyms, while maintaining the tactile sensation and inertia of moving physical weights.

Moreover, the electromechanical resistance module can be used as a structural part, such as a crossbar, in a power rack. Its housing, for example made of a solid 1080×400×150 mm structure, is stable and stiff enough to replace the full connecting element of a power rack, typically referred to as a crossbar. By replacing the top crossbar of a power rack with this module, users can perform lat-pulldowns while saving between 70 cm and 100 cm in power rack depth. Mounting the electromechanical resistance module at the top of the machine also frees up valuable space at the bottom, which can be used for a bench or other equipment. This design provides the same shape and stability of a compact power rack but with a built-in electromechanical resistance module.

In this context, the housing is preferably constructed from durable materials such as metal, steel, or fiber-reinforced plastic, as well as other high-strength composites. This robust construction allows for example the electromechanical resistance module to be integrated into power racks as a structural component, replacing a traditional crossbar. By serving both as a structural element and a source of resistance, the electromechanical resistance module optimizes space and functionality in the workout setup.

In a further preferred embodiment, the electromechanical resistance module comprises a control unit with a data processing unit for controlling the second resistance source, memory and a communication unit for data communication. The inclusion of a control unit with a data processing unit, especially in combination with sensors measuring conventional iron-weights moved and electrical resistance provided, enables the machine to offer dynamic resistance adjustments based on real-time feedback. This can enhance the effectiveness of workouts by automatically adapting resistance to the user's performance. The communication unit allows for data exchange with external devices or networks, providing opportunities for remote monitoring, software updates, and integration with fitness tracking systems. The control unit's ability to manage the second resistance source ensures a seamless and user-friendly experience, as it can automatically calibrate resistance levels in response to programmed workout routines or user preferences.

In general, the user interface allows a user to exert force against a resistance in order to exercise muscles. The user interface may take a variety of forms, including (but not limited to) a single handle, a long bar handle, a lat pull-down handle, a rope, etc.

Additionally, embodiments are also possible in which the user interface may comprise means for providing an input signal to the control unit. The user interface's provision for input signals to the control unit allows users to easily customize their workout experience by selecting desired resistance levels, exercise durations, and other parameters, thereby improving user satisfaction and workout personalization. The means for providing input signals can include various user-friendly options such as buttons, rotational adjustment rings, touchscreens, or microphones for voice commands, which can enhance accessibility. By enabling direct user interaction with the control unit, the user interface facilitates immediate adjustments to the workout, allowing users to quickly respond to their own comfort and performance levels, which can lead to more effective and enjoyable exercise sessions. The user interface preferably comprises a communication unit and a rechargeable battery which allows to transmit the input signals to the electromechanical resistance module. It can also comprise a memory or a data processing unit.

Preferably, the user interface is designed as a handle featuring a rotational adjustment ring and a haptic button that allows the user to increase, decrease, or stop the electromechanical resistance. Operated with only one finger, this technology can be seen as a One-Thumb control. Different sizes and shapes of handles are preferably available depending on the exercise.

The user can start their training using only physical weights and activate the electromechanical resistance from the electromechanical resistance module with a simple thumb rotation on the handle. The handle can be battery-powered, and the battery can be charged with a USB-C cable by plugging it directly into the electromechanical resistance module. The signal from the handle may be transferred wirelessly to the electromechanical resistance module.

In a further preferred embodiment, the exercise machine comprises a sensor system configured to acquire the resistance of the first resistance source and/or the second resistance source and/or the single output resistance and/or the movement of the physical weight and/or the force applied to the adapter and/or the movement of the first cable, the second cable and/or the adapter. In this respect, the sensor system comprises means for providing acquired data to the control unit.

Preferably the sensor system comprises at least one sensor, a battery and a communication unit. Furthermore, the sensor system can comprise a data processing unit, a memory and a housing which accommodates all components.