Hypotrochoid assembly for generating vibrations in an exercise machine and method for using same

1. A hypotrochoid apparatus for creating vibrations in an exercise machine, comprising:

an inner assembly and an outer assembly;

the inner assembly comprising a spindle, an eccentric hub, bearings, a key, a retaining ring, and an external involute gear, said spindle being located inside the inner assembly and having a spindle proximate end and a spindle distal end, wherein said spindle proximate end and said spindle distal end each comprises at least one mechanical interface;

a groove that runs around an outer circumference of the spindle for engaging an inner retainer ring, and the key positioned parallel to a longitudinal length of the spindle;

a first sealed bearing of the bearings mounted on the spindle proximate end;

a second sealed bearing of the bearings mounted on the spindle distal end, and the first sealed bearing and the second sealed bearing rotatably support the spindle;

the eccentric hub comprising a central throughbore for receiving the spindle, wherein the spindle is rotatably engaged with the eccentric hub and an inner bore enhances vibration when the spindle is rotating and the eccentric hub is engaged;

a first angular contact ball bearing of the bearings comprising a distal side and a proximate side and centrally mounted around the outer surface of the eccentric hub; and

a second angular contact ball bearing of the bearings comprising a distal side and a proximate side being centrally mounted around the outer surface of the eccentric hub, wherein the proximate side of the first angular contact ball bearing abuts the distal side of the second angular contact ball bearing.

2. The hypotrochoid apparatus of claim 1 , further comprising a first lock washer being engaged the distal side of the first angular contact ball bearing and a second lock washer engaged with the proximate side of the second angular contact ball bearing.

3. The hypotrochoid apparatus of claim 1 , further comprising a first lock nut being engaged with a first lock washer and a second lock nut being engaged with a second lock washer.

4. The hypotrochoid apparatus of claim 1 , wherein the external involute gear comprises a single planet gear comprising a key way for engaging the key and teeth surrounding an outer circumference the single planet gear.

5. The hypotrochoid apparatus of claim 1 , wherein the outer assembly comprises an outer hollow housing being cylindrically shaped and having a proximate end and a distal end, a first retaining ring being positioned inside the outer hollow housing at the proximate end of the outer hollow housing.

6. The hypotrochoid apparatus of claim 5 , wherein the outer assembly comprises a rotor clutch assembly positioned at the distal end of the outer hollow housing.

7. The hypotrochoid apparatus of claim 4 , wherein the external involute gear comprises a single ring gear comprising teeth surrounding an inner circumference of the single ring gear for meshing with the teeth surrounding the outer circumference of the single planet gear of the inner assembly.

8. The hypotrochoid apparatus of claim 6 , further comprising a ring shaped shim comprising a central opening, an inner surface, and an outer surface for closing a gap between the first retaining ring and the proximate end of the outer hollow housing after the inner assembly is concentrically coupled within the outer hollow housing, wherein the inner surface of the shim is abutted against the first retaining ring.

9. The hypotrochoid apparatus of claim 8 , further comprising a second retaining ring positioned inside the proximate end of the outer hollow housing and abutted against the outer surface of the shim.

10. The hypotrochoid apparatus of claim 1 , wherein the inner assembly is concentrically coupled within the outer assembly, and the at least one mechanical interface is coupled to a crank arm.

11. The hypotrochoid apparatus of claim 6 , further comprising a clutch system to control the rotor clutch assembly and engage or disengage vibration.

12. A hypotrochoid apparatus for creating vibrations in an exercise machine, comprising:

an inner assembly and an outer assembly, wherein the outer assembly comprises an outer hollow housing having a proximate end and a distal end;

the inner assembly comprising a spindle, an eccentric hub, bearings, a key, a retaining ring, and an external involute gear, said spindle being located inside the inner assembly and having a spindle proximate end and a spindle distal end, wherein said spindle proximate end and said spindle distal end each comprises at least one mechanical interface;

a groove that runs around an outer circumference of the spindle for engaging an inner retainer ring, and the key positioned parallel to a longitudinal length of the spindle;

a first sealed bearing of the bearings mounted on the spindle proximate end;

a second sealed bearing of the bearings mounted on the spindle distal end, and the first sealed bearing and the second sealed bearing rotatably support the spindle;

the eccentric hub comprising a central throughbore for receiving the spindle, wherein the spindle is rotatably engaged with the eccentric hub and an inner bore enhances vibration when the spindle is rotating and the eccentric hub is engaged;

a first angular contact ball bearing of the bearings comprising a distal side and a proximate side and centrally mounted around the outer surface of the eccentric hub;

a second angular contact ball bearing of the bearings comprising a distal side and a proximate side being centrally mounted around the outer surface of the eccentric hub, wherein the proximate side of the first angular contact ball bearing abuts the distal side of the second angular contact ball bearing;

a belt tensioner system;

a rotor clutch assembly positioned at the distal end of the outer hollow housing; and

a clutch system to control the rotor clutch assembly and engage or disengage vibration comprising a clutch, clutch lever, clutch pin, clutch pin link, clutch pressboard, and clutch cable mount.

13. The hypotrochoid apparatus of claim 12 , wherein the clutch system further comprises a clutch mount cover.

14. The hypotrochoid apparatus of claim 12 , wherein the clutch system further comprises a clutch cover.

15. The hypotrochoid apparatus of claim 12 , wherein the clutch is an axis clutch.

16. A method for making hypotrochoid apparatus for creating vibrations in an exercise machine, the steps comprising:

assembling an inner assembly comprising a spindle, an eccentric hub, bearings, a key, a retaining ring, and an external involute gear, said spindle being located inside the inner assembly and having a spindle proximate end and a spindle distal end, wherein said spindle proximate end and said spindle distal end each comprises at least one mechanical interface;

creating a groove that runs around an outer circumference of the spindle for engaging an inner retainer ring;

positioning the key on top of, and parallel to a longitudinal length of, the spindle;

mounting a first sealed bearing of the bearings on the spindle proximate end;

mounting a second sealed bearing of the bearings on the spindle distal end, and the first sealed bearing and the second sealed bearing rotatably support the spindle;

forming the eccentric hub comprising a central throughbore for receiving the spindle, wherein the spindle is rotatably engaged with the eccentric hub and an inner bore enhances vibration when the spindle is rotating and the eccentric hub is engaged;

mounting a first angular contact ball bearing of the bearings comprising a distal side and a proximate side centrally around the outer surface of the eccentric hub; and

mounting a second angular contact ball bearing of the bearings comprising a distal side and a proximate side centrally around the outer surface of the eccentric hub.

17. The method of claim 16 further comprising:

assembling an outer assembly comprising an outer housing having a proximate end and a distal end, wherein the inner assembly is positioned within the outer assembly;

assembling a rotor clutch assembly; and

housing the rotor clutch assembly at the distal end of the outer housing.

18. The method of claim 17 further comprising:

controlling the rotor clutch assembly with a clutch system, wherein the rotor clutch assembly engages or disengages the eccentric hub vibration and the clutch system comprises a clutch, clutch lever, clutch pin, clutch pin link, clutch pressboard, and clutch cable mount.

19. The method of claim 17 further comprising:

assembling a clutch system comprising a clutch, clutch lever, clutch pin, clutch pin link, clutch pressboard, and clutch cable mount.

20. The method of claim 17 further comprising:

engaging the clutch system to the rotor clutch assembly by inserting the clutch pin into a coupling located on the outer surface of the rotor clutch assembly.