# US 11,077,330 B2 · Exercise machine with pancake motor

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- Number: US 11,077,330 B2
- Document ID: US11077330B2
- Status: Granted
- Kind: B2
- Application number: 17/081,950
- Filed: 2020-10-27
- Published: 2021-02-11
- Granted: 2021-08-03
- Earliest claimed: 2017-10-02
- Assignees: Tonal Systems, Inc.
- Applicants: Tonal Systems, Inc.
- Inventors: Aly E. Orady; Michael Valente
- Web page: https://patentgrep.com/patent/US11077330B2

## CPC

- A63B 21/0058: {using motors}
- A63B 21/0051: {using eddy currents induced in moved elements, e.g. by permanent magnets}
- A63B 21/015: including rotating or oscillating elements {rubbing against fixed elements}
- A63B 21/15: {Arrangements for force transmissions}
- A63B 21/153: {wound-up and unwound during exercise, e.g. from a reel}
- A63B 21/154: {using special pulley-assemblies}
- A63B 21/156: {the position of the pulleys being variable, e.g. for different exercises}
- A63B 21/169: {for anchoring on or against a wall}
- A63B 21/4035: {for operation by hand}
- A63B 21/4043: {Free movement, i.e. the only restriction coming from the resistance (A63B21/00043, A63B21/072 take precedence)}
- A63B 23/03541: {Moving independently from each other (A63B22/00 takes precedence)}
- A63B 23/12: for upper limbs {or related muscles, e.g. chest, upper back or shoulder muscles (bench press exercises A63B21/078; for teaching music G09B15/06)}
- A63B 24/0087: {Electric or electronic controls for exercising apparatus of groups A63B21/00 - A63B23/00, e.g. controlling load}
- A63B 71/0054: {Features for injury prevention on an apparatus, e.g. shock absorbers (mats or the like for absorbing shocks for jumping A63B6/00)}
- A63B 21/4045: {Reciprocating movement along, in or on a guide (weights moving along or in guiding means A63B21/06; for cardio-training A63B22/201)}
- A63B 2024/0093: {the load of the exercise apparatus being controlled by performance parameters, e.g. distance or speed}
- A63B 2071/0072: {Limiting the applied force, torque, movement or speed}
- A63B 2071/0081: {Stopping the operation of the apparatus}
- A63B 2210/50: Size reducing arrangements for stowing or transport
- A63B 2220/13: Relative positions
- A63B 2220/36: Speed measurement by electric or magnetic parameters
- A63B 2220/40: Acceleration
- A63B 2220/51: Force
- A63B 2220/54: Torque
- A63B 2220/58: Measurement of force related parameters by electric or magnetic means
- A63B 2220/72: Temperature
- A63B 2220/805: Optical or opto-electronic sensors
- A63B 2220/833: Sensors arranged on the exercise apparatus or sports implement
- A63B 2220/89: Field sensors, e.g. radar systems
- A63B 2225/09: Adjustable dimensions
- A63B 2225/093: Height
- A63B 2225/50: Wireless data transmission, e.g. by radio transmitters or telemetry
- A63B 2225/54: Transponders, e.g. RFID
- A63B: APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT (apparatus for passive exercising, massage A61H)

## Abstract

An exercise machine is disclosed. The exercise machine comprises a pancake motor. The exercise machine comprises a torque controller coupled to the pancake motor. The exercise machine comprises a high resolution encoder coupled to the pancake motor.

## Claims

### Claim 1

An exercise machine comprising:
a pancake motor, wherein the pancake motor is in an out-runner configuration;
a torque controller coupled to the pancake motor;
a spool coupled to the pancake motor, and a cable wound about the spool; and
at least one encoder, wherein the at least one encoder determines at least one of position of the pancake motor and position of an actuator; and
wherein the pancake motor uses cable tension and gravity to move a slider up and down to desired positions for an arm.

### Claim 2 (depends on 1)

The exercise machine of claim 1, further comprising a voltage stabilizer coupled to the pancake motor to dissipate power.

### Claim 3 (depends on 1)

The exercise machine of claim 1, further comprising an encoding pattern that uses phase to determine direction associated with the at least one encoder.

### Claim 4 (depends on 1)

The exercise machine of claim 1, wherein the arm positions the cable.

### Claim 5 (depends on 4)

The exercise machine of claim 4, wherein the arm has an ability to pivot.

### Claim 6 (depends on 4)

The exercise machine of claim 4, wherein the arm has an ability to translate.

### Claim 7 (depends on 1)

The exercise machine of claim 1, wherein the exercise machine is a strength training machine.

### Claim 8 (depends on 1)

The exercise machine of claim 1, further comprising a differential coupled to the pancake motor.

### Claim 9 (depends on 8)

The exercise machine of claim 8, wherein the spool comprises a first spool, and further comprising a second spool, wherein each spool is coupled to the differential.

### Claim 10 (depends on 9)

The exercise machine of claim 9, wherein the arm comprises a first arm, wherein the cable comprises a first cable, and further comprising: a second arm; and a second cable, wherein: the first cable is wound about the first spool; the second cable is wound about the second spool; the first arm positions the first cable; and the second arm positions the second cable.

### Claim 11 (depends on 10)

The exercise machine of claim 10, wherein the pancake motor, first spool, and second spool are mounted near a top of the exercise machine.

### Claim 12 (depends on 10)

The exercise machine of claim 10, wherein the pancake motor, first spool, and second spool are mounted near a bottom of the exercise machine.

### Claim 13 (depends on 10)

The exercise machine of claim 10, wherein the first cable and the second cable are routed over a top of the exercise machine.

### Claim 14 (depends on 1)

The exercise machine of claim 1, further comprising a low profile gear box coupled to the pancake motor.

### Claim 15 (depends on 1)

The exercise machine of claim 1, further comprising a low profile differential coupled to the pancake motor.

### Claim 16 (depends on 1)

The exercise machine of claim 1, wherein the exercise machine is low profile.

### Claim 17 (depends on 1)

The exercise machine of claim 1, wherein the pancake motor comprises a first pancake motor, and further comprising a second pancake motor.

### Claim 18 (depends on 17)

The exercise machine of claim 17, wherein the spool comprises a first spool, and further comprising a second spool, wherein the first spool is coupled to the pancake motor, and wherein the second spool is coupled to the second pancake motor.

### Claim 19 (depends on 18)

The exercise machine of claim 18, wherein the arm comprises a first arm, wherein the cable comprises a first cable, and further comprising: a second arm; and a second cable, and wherein: the first cable is wound about the first spool; the second cable is wound about the second spool; the first arm positions the first cable; and the second arm positions the second cable.

### Claim 20 (depends on 1)

The exercise machine of claim 1, further comprising a wall bracket, wherein the exercise machine at least in part hangs on the wall bracket.

### Claim 21 (depends on 1)

The exercise machine of claim 1, wherein the pancake motor has teeth compatible with a belt integrated into a body of the pancake motor along an outer circumference.