The 14th IFToMM World Congress, Taipei, Taiwan, October 25-30, 2015
DOI Number: 10.6567/IFToMM.14TH.WC.PS8.004
Study of new type elliptical cross trainer with symmetrical driving mechanism
Francois Liang1
Cycling and health tech. industry R&D center
Taichung , Taiwan
Abstract: The elliptical cross trainer (hereinafter referred
to as E.C.T.) is a type of indoor fitness equipment. Similar
to the treadmill, the E.C.T. provides a type of exercise
based on the gait of walking or running. With a lower
impact effect on the user's knee, the E.C.T. is becoming
increasingly popular. However, there are limitations to its
design when just using the existing types of E.C.T.
mechanisms.
This study focuses on function requirements that have not
been realized in existing designs and making them tasks of
the new E.C.T. design. We perform synthesis of the new
mechanism type by using the kinematic chain, TRIZ
method, and gait theory. Afterward, dimensional synthesis
is carried out by using vector loop analysis. Finally, we
realized a design and a prototype of the new E.C.T. to
prove the results of the design.
The new E.C.T. possesses the following four features(a)
less floor space requirements(b) a more suitable pedal
angle that meets the gait(c) smaller and adjustable pedal
spacing (d) with a similar view as real walking or
running.
Keywords: Symmetrical, Elliptical, Gait
I. Introduction
Among indoor fitness equipment, the elliptical cross
trainer (E.C.T.) has been developed lately, but in todays
fitness equipment market, it is favored by consumers and
keeps pace with products developed earlier, such as
treadmills, stationary bicycles, etc. and shows its
substantial advantages and product charm. The market
demand has also made this type of equipment become very
diverse.
Current E.C.T. designs are mainly based on the linkage
type mechanism. Because the pedal operation pattern of
E.C.T. has continuous reciprocating movement
characteristics, the products that are currently sold are
mostly designed with four-bar linkage and six-bar linkage
mechanisms. Regardless of the kind of design, the current
mechanism configuration makes this equipment require a
large floor area. As indoor sports needs are focused in
metropolitan areas, the use of space is relatively important.
If space can be used effectively, it would be a big benefit.
This study attempts to develop an innovative sport
mechanism by placing crank structure in the center, letting
the crank be the center of the overall mechanism with a
forward and backward extended symmetrical structure to
avoid using the horizontal slide mechanism, thus reducing
the space required.
1
ali@tbnet.org.tw
2
jesse@tbnet.org.tw
Chia-Hsun Chuang2
Cycling and health tech. industry R&D center
Taichung , Taiwan
Furthermore, previous studies or improvement to the
E.C.T. regarding trajectory parameters have mainly been
directed at stride adjustment or trajectory shape modify. In
fact, for users, the step width is also an important
parameter. Current E.C.T. products can accommodate the
design condition of the crank - pulley structure and
flywheel set configuration, but have inherent limits to the
minimum horizontal distance between the two pedals,
regardless of the actual gait step width difference. This
study also expects to escape the conventional mechanism
configuration method to minimize the horizontal distance
between the two pedals, in addition to focusing on the
development of a new type of elliptical path mechanism.
Furthermore, the trampling angle and the improvement of
the exercise situation will also be considered when
innovating and configuring the mechanism. E.C.T.
products can be divided into many categories. In addition
to operation in the standing posture, there are also those in
sitting or lying postures. The scope of the study is mainly
operation in the standing posture and models with
horizontal or nearly horizontal trajectory long axis.
II. Theories
A . TRIZ method
The TRIZ method has two main problem-solving skills;
one is the contradiction matrix, and the other is substance -
field analysis. The contradiction matrix is one of the most
commonly used problem-solving methods and is also the
method applied in this research.
When solving a paradox, first one must deal with its
conflicts to confirm if its type is a technical contradiction
or physical contradiction and then decide which
problem-solving method to use. "Technical contradiction"
solutions typically use the contradiction matrix as the main
problem-solving tool, while "physical conflicts" use the
separation principles to resolve their conflicts.
The contradiction matrix is the principal means for solving
technical contradictions and its constituent subjects are 39
engineering parameters and 40 inventive principles. Table
1 shows the partial contents of a contradiction matrix; the
39 engineering parameters are listed in the upper and left
sides of the matrix, representing the improving parameters
and worsening parameters of the contradiction problem,
respectively, with each cell entry formed by any improving
parameter and worsening parameter giving the most often
used inventive principles that can be used to eliminate the
contradiction. For example, numbers 38, 8, 2, and 14 in the
entry are four symbols of the 40 inventive principles that
were advised to solve the contradiction problem.
 TABLE 1. Partial contents of the contradiction matrix [1]
B. Dyad and vector loop
Before carrying out location analysis on the vector pair
(Dyad) [2], the vector changes of a singular vector must
first be analyzed in different directions. Figure 1 shows the
definitions and relations of the bar vectors parameters
when the free endpoint of a bar moves from P1 to P2:
Fig. 1. Representation and parameter definition of vector position
change
A known vector before moving and after moving can be
expressed as:
W = w e i w , W1 = w e i w1
andso w1 = w + 1
so W1 = w e i w e i 1
The relationship before and after vector moving with the
moving angle 1 can be obtained from the above
assumptions.
W1 = W e i 1
Based on Formula 1, the vector loop equation can be
derived from the vector change before and after the vector
pairs displacement. For example, the four-bar linkage
shown in Figure 2 has the free end of the Dyad formed by
vector W and vector Z and moves from point P1 to point
Pj. The following vector loop equation can be derived from
the vector relationship before and after movement:
W e i j+ Z e i j R j + R1 - Z - W =0
Rj R1 = j
W ( e i j-1)+ Z ( e i j -1) = j
Fig. 2. Diagram of the vector pairs displacement change of the linkage
mechanism
For known vectors and the formed vector pair, Formula 3
can be obtained from the relationship of the vector of the
free end and vector displacement angles j and j .
C. Gait
Gait refers to a persons manner of walking from one foot
touching the ground to the same foot touching the ground
again. Gait studies generally begin with one foot touching
the ground and end with the same foot touching the ground
again as a cycle [3]. A gait cycle can be divided into stance
phase and swing phase [4], where stance phase is the
course from the heel touching the ground to the toe lift and
swing phase is the course from the toe lift to the heel
touching the ground again. The stance phase is shown in
Figure 3 (a) and the swing phase in Figure 3 (b).
Fig. 3. Continuous actions of stance phase (a) and swing phase (b) [5]
The captured foot tracks through a treadmill look like
water-drop closed curves, as shown in Figure 4. Figure 5 is
the diagram of the relationship between leg movement and
foot moving tracks during one cycle.
(1)
Fig. 4. Gait foot tracks on a treadmill [6]
(2)
(3) Fig. 5. Relationship between leg movement and foot tracks [6]
However, the results of treadmill simulation are still
slightly different from actual walking on ground [7].
Furthermore, the size and shape of the tracks will be
affected by walking speed, gait cycle, height, walking
habits and other factors. When operating an E.C.T., the
shift of the users center of gravity is limited, as shown in
Figure 6. It is different from the true walking manner in
which the human body must first shift his center of gravity
to his forefoot, as shown in Figure 7.

Fig. 6. Movement tracks of the human bodys center of mass on the

sagittal plane [8]

Fig. 7. Shift of center of gravity in gait [9]

Hence, in the design of gait simulation equipment, it is

impossible for the movement track of a fixed size and
fixed-shape curve to meet all operating conditions. A Fig. 8. Angle changes of lower limb joints in an ideal gait [9]
single track curve is just one gait performance under a
certain condition, but not the only result.
The hip, knee, and ankle joints are the three major joints
dominating lower limb movements. Through a series of
different combinations of joint angles, the ends of limb
segments in each action sequence can be made to reach the
desired position.

In this study, when setting pedal angles of an E.C.T. at the

two before and after turn points of the track, the angle of
the front foot pedal uses the angle of the foot at the initial
contact point (0%) as a reference, and the back foot pedal
uses the angle of the foot at the middle segment (55%) of
the overlapping region in the two feet stance phases as a
reference. The results in Figure 8 are calculated with the
measured data of joint angles to get Figure 9. And thus to
set the target of pedal angles to be about 21 degree for new
E.C.T. .
Fig. 9. Angles of two soles relative to the ground when striding
III. Methods
A. Modification of structure layout
By applying TRIZ theory, from the two contradiction
parameters "Length of stationary object" and "Area of
stationary object", four solutions to the machine space
problem are obtained: moving to a new dimension, Nesting,
Prior Action, and Composite Materials. The most feasible
one is "Nesting". Therefore, we should select a mechanism
layout of a symmetrical design such that the floor
projection ranges of the mechanism and track can overlap.
By applying TRIZ theory, from the two contradiction
parameters "shape" and "Length of moving object", four should not overlap with the pivot points of the above
solutions to the crank over-length problem are obtained: four-bar linkage set. Therefore, the frame must have at
asymmetric, combination (integration), using pneumatic or least three pivot points set as three joint linkage
hydraulic construction, and Rejecting and Regenerating components. If C stands for crank, G for frame, and R for
Parts. The most feasible one is "combination (integration)". swing bar, the basic linkage assembly as shown in Figure
Therefore, the kinematic mechanism must be combined 10 is available.
with the amplification mechanism to appropriately extend
the stroke provided by the crank.
By applying TRIZ theory, from the two contradiction
parameters "shape" and "ease of use", three solutions to the
not-ideal pedal angle problem are obtained: changing color,
dynamicity and copying. The most feasible one is
"dynamic". The existing deficiency is improved through
proper segmentation of the pedal and linkage such that Fig. 10. Basic linkage assemblies that meet the requirements
both can have relative motion.
By applying TRIZ theory, from the two contradiction Constrained by the aforementioned conditions, there are
parameters "reliability" and "object-generated harmful two types of six-bar linkage that could meet the
factors", four solutions to the not-ideal operation situation requirements as shown in Figure 11. Among them, only the
are obtained: transformation of physical or chemical states Stephenson III six-bar linkage mechanism in Figure 11 (b)
of an object, extraction, composite materials, and copying. can meet the design targets.
The most feasible one is "extraction". The negative result
from structure layout can be avoided by extracting
structures that cause spatial pressure to be reassigned to a
location that does not have a similar impact.

B. Selection of mechanism type

Because an E.C.T. requires an approximate elliptical
closed track to guide the human bodys lower limbs to (a) ( b)
exercise like walking, using a linkage mechanism is Fig. 11. Possible types of mechanisms after initial filtering
appropriate.
This study assumes that gait motion is planar motion, and This configuration can be seen as a set of four-bar linkage
the output of the mechanism is close to the default track in combination with two two-joint links. The typical crank
curve. In consideration of the commercialization limit to rocker type four-bar linkage set, regardless of how to the
the number of linkages, using a six-bar seven-joint planar link is configured, is unlikely to make a couple curve and
linkage mechanism is appropriate. mechanism configuration to the crank rotation center have
In application of the modification of Gruebler's equation, symmetric distribution; the only way is to use the
the possible combinations of a six-bar linkage mechanism substitution of an equivalent mechanism to convert the
are found to have eight basic types, of which only two crank-rocker to the crank-slider mechanism, as shown in
basic types are of practical value, that is, the Watt six-bar Figure 12. To make the output trajectories symmetrical to
linkage and Stephenson six-bar linkage mechanisms. the crank axis, taking the inverted type crank-slider
Therefore, the new E.C.T. developed in this study uses the mechanism would be the best option.
above two six-bar mechanisms as its basis for assessment.
Furthermore, in order to simplify the mechanical
appearance, reduce cost, and avoid interference between
mechanisms, this study makes selections by using the
single-connector link bar. No mechanical components are
set between the two pedals, and the lateral spacing of
pedals can be adjusted by a structure that must be capable
of sideways adjustments.

C. Kinematic chains and mechanism synthesis

First, the crank layout is decided. Because the crank has a
rotating motion, the crank is designed to be a simple
two-joint bar.
Four-bar linkage is the most basic requirement for the
formation of a closed coupler curve. Therefore, the
kinematic mechanism must contain at least one four-bar
linkage that meets the Grashoff principle and must have
two pivot points on the ground bar, which is usually the
frame, that is, the frame has at least two fixed pivot points.
In addition, the crank is connected to the ground bar.
Because pedal angle is controlled by a swing bar, the frame
must have a pivot as the connection point of the swing bar;
because the complex joint is not used, this pivot joint
Fig. 12. Available crank-slider mechanisms
In order not to make the long axis of elliptical movement
trajectories be directly limited by crank length, the creation
point to generate the trajectory of the coupler curve cannot
be located between point a and point o , as shown in Figure
13. If the creation point to generate the trajectory of a
coupler curve is put at point c , because cd must be greater
than or equal to ab , only a few extensions of point c will
enlarge the displacement effect.

Fig. 13. Output location selection of the crank-slider mechanism
By using the concept of an instantaneous center, after
reasonably simplifying the structure of the selected six-bar
mechanisms, we can simplify the original six-bar
mechanisms into four-bar linkage G -L2-L4-L5, as shown
in Figure 14.
Fig. 14. Equivalent mechanisms
If L2 is regarded as the virtual crank of G -L2-L4-L5
four-bar linkage set and conforms with the foregoing
symmetrical design, then because the structure of the
four-bar linkage G-L1-L2-L3 and output curve can meet
the symmetric distribution to the rotation center of crank
L1, the virtual rotation center of L2 should also be located
on the center line of G-L1-L2-L3 four-bar linkage
structure.
Again, from the inverted crank-slider mechanism
conversion and the aforementioned enlargement principle
of similar triangles, we know that the output points must be
placed in the external extension line of coupler link L4, as
shown in Figure 15.
Fig. 15. Output point design of equivalent four-bar linkage set
Next, L2 virtual bar is converted into G-L1-L2-L3 linkage
set and L2 virtual bar is replaced by applying the output
end of the G-L1-L2-L3 linkage set to the input end of the G
-L2-L4-L5 linkage set, as shown in Figure 16.
Fig. 16. Synthesis of six-bar mechanisms
Slider L3 and slider L5 entities are appropriately extended
to gain support by making L2 and L4 links have sufficient
lengths on the sliding stroke to overlap with sliders L3 and
L5 so as to more efficiently use space, as shown in Figure
17.
Fig. 17. New mechanism types and their simple physical component
configuration
D. Mechanism dimension
From gait study results, gait trajectories are not fixed and
are affected by many factors; furthermore, gait cycles of an
E.C.T. are different from actual gaits, so if water-drop
shaped gait trajectories are used, the effect is limited and
prone to mechanism dead points that are not favorable to
movement. Therefore, the new E.C.T. still selects a
near-elliptical trajectory design, but the bottom curve is
slightly flatter than the top half.
Fig. 18. Coordinate origin of elliptical trajectory and targets of the size
The linkage mechanism model of the new E.C.T. as shown
in Figure 17 is converted into a vector diagram for the
calculation of dimension synthesis. The vector diagram
when the linkage mechanism output endpoint passes point
p is as shown in Figure 19. P1, P2, P3 and P4 are
respectively located at the intersections of the elliptical
trajectory and its long and short axes.
Fig. 19. Linkage mechanism vector diagram
Based on the vector diagram in Figure 19, we capture
different vector loops in accordance with gait trajectory
and the constraint conditions formed by mechanism type.
By using the vector loops in Figure 20 and passing them
through different trajectory outputs (P , P2, P3) , the crank
length is determined to be 75 mm.
By using link position changes, the vector loops in Figures
24 ~ 26 are obtained. Regarding the aforesaid obtained
dimension parameters, the distance between the lower
swing bar pivot and the drive shaft axis is 254 mm.

Fig. 20. Vector loop passing through different trajectory outputs

By using the vector loop in Figure 21, the distance Ra 0

between the pivot position of the upper swing bar and the
trajectory coordinate origin is found to be 703 mm.

Fig. 24. Linkage vector relationships when the output end point is moved
from P1 to P2

Fig. 21. Vector loop from upper swing bar pivot to the output point P1

By using the vector loops in Figure 20 and the

configuration planning in Figure 22, the vertical distance
between the pedal surface and drive shaft axis at position
P3 should be 105 mm.
Fig. 25. Vector loop formed by L1, L2 and L4 links

Fig. 26. Vector loop formed by L1 and L3 links and the ground bar
Fig. 22. Diagram of the relative position between pedal and drive shaft

According to the tradeoff on both the enlarged size and By using the solutions to various constraints and vector
impact of link length, L2 and L4 link lengths are 400 mm loops, the main link sizes can be obtained as shown in
and 220 mm, respectively. Figure 27.

Fig. 23. Dimenhsion parameters of the enlargement mechanism

Fig. 27. Dimensions of the main links
IV. CAD modeling
After completing the mechanism configuration and
dimensions, CAD software is used for the physical design
in order to convert the theoretical mechanism model into a
practical prototype of the product.

Fig. 32. Appearance of assembly-completed prototype

V. Results and discussions

Fig. 28. Main frame structure and linkage components (1)
With respect to machine space configuration, the new
E.C.T. of this study has used leverage amplification to
make its crank length shorter than a traditional E.C.T., but
it can reach the same long axis length of an elliptical
trajectory. The crank length of this new E.C.T. is 75 mm,
which can generate an elliptical trajectory of a long axis up
to 540 mm, compared to the elliptical trajectory of a long
axis that is only 150 mm when generated by the traditional
E.C.T. design. Furthermore, the linkage of the new E.C.T.
is located on both sides. The created elliptical trajectory
lies between the linkage sides and does not exceed the
bottom area range of the machine body. Therefore, the new
design does not take up space outside the main structure of
the machine body and can thus obtain optimal space
configuration.

Manufa Commercial Commercial Commercial

This study
cturers product 1 product 2 product 3
Linkage six-bar six-bar
four-bar four-bar
type (Stephenson III) (Watt II)

( 21.2) 21.2 21 21
Fig. 29. Main frame structure and linkage components (2) Stride
540mm ( 540mm ) (533mm) (533mm)

Floor (31.5 x 51 ) 32 x 80 25 x 85 31 x 68.5

space 80 x 130 cm (81 x 203 cm) (63.5 X 216 cm) (78.7 X 174 cm)

Floor
10400 cm2 16443 cm2 13716 cm2 13694 cm2
area
TABLE 2. Comparison table of E.C.T. floor area

Table 2 shows the floor area comparison between the new

E.C.T. prototype and currently available commercial
products with similar step length specifications. We can see
Fig. 30. Resistance and transmission system that the new E.C.T. prototype has less space requirements.

In addition to enhancing function, the new E.C.T. of this

study does not produce difficulties from operation or drive
though it uses a linkage different from the traditional
design. By using ADAMS to analyze the constant speed
drive of three E.C.T.s on the market, as well as the new
E.C.T., the needed torque supply of the new E.C.T.
(product d) is found to be between product a and product b,
that is, the drivability of the new E.C.T. is similar to the
E.C.T.s on the market. Therefore, the driving
characteristics of the new E.C.T. are not much different
from E.C.T.s on the market and runs without problems.
Meanwhile, it can use the resistance unit that is currently
Fig. 31. External perspective views
used in general E.C.T.s on the market without further
development, as shown in Figure 33.

product (a)
product (b)
product (c)
product (d)
Fig. 33. Drivability comparisons of commercial products with the new
E.C.T.
With respect to pedal spacing, the measured pedal spacing
of the prototype is 50 mm~170 mm, as shown in Figure 34.
In fact, if the pedal fixture is extended more to the machine
platform center, the pedal adjustment range can be
increased to obtain less pedal spacing.
Fig. 34. Prototype pedal spacing measurements
Regarding pedal angle, the angle measured using the angle
measurement device when the pedal reaches the rear two
front and back limit positions of the trajectorys long axis is
about 21, as shown in Figure 35.
Fig. 35. Prototype pedal angle measurements
This study defines four targets for the new E.C.T.: must
have better spatial configuration of the machine body, a
proper pedal angle, better pedal lateral spacing, and better
movement vision. The study results show that the above
objectives have all been achieved.
It means that the new E.C.T. needs less floor area and the
motion type is more approaching to the natural gait,
furthermore, provided more comfortability for human use.
VI. Industrial applications and derived benefits
The technology developed in this study uses a linkage
type kinematic mechanism to simulate the walking gait
function; it can achieve a gait movement similar to
walking or running and is equipped with the
magnetically controlled resistance system. The new
E.C.T. does not only provides resistance Training; it
also combines multiple functions, such as lower limb
muscle strength and muscle endurance training, and the
cardio aerobic exercise training. Whether general
household leisure fitness, commercial exercise training
courses or professional athletes training, or even sports
rehabilitation for mild limb obstacles, all of the above
are applications to which the study results may be
dedicated. Furthermore, because this study breaks
through the configuration and limitations of a traditional
E.C.T. and also provides the industry with a different
reference and design thinking in designing new
products to help the industry escape the existing E.C.T.
design bottlenecks.
VII. Conclusions
Since the first E.C.T. was developed, along with the
continuous innovation research of academics and the
industry, mechanism types of products have become
diverse in order to offer consumers more choices, making
E.C.T.s one of the most popular products and providing a
better platform for innovation research.
Although the kinematic mechanism of the E.C.T. has
continued to evolve, the type still remains in a similar
design concept, which makes the E.C.T. unable to escape
the stereotypes of mechanized operations. Although the
operation of the lower limbs is akin to gait movement, it
has a very different sense of context compared with natural
walking and running. Therefore, in this study, in addition
to being committed to the innovation of a kinematic
mechanism, we escape traditional E.C.T. thinking types to
create a less space-stress platform so that users can be more
relaxed when exercising. Secondly, in recent years, some
studies have also been committed to improving the gait
characteristics of the E.C.T., but the focuses have been
more on movement trajectory research and creation.
However, because of the factors that actually affect gait
characteristics are not only limited to movement trajectory,
and the human body motion of the E.C.T. belongs to the
closed kinematic chain which is different from the open
kinematic chain of the foot on the ground, the correction of
movement trajectory has certain restrictions to
improvement. Therefore, in addition to setting the
appropriate size of trajectory, this study considers
reasonable step stampede angle as one of the factors for the
mechanism creation, rather than focusing on the creation
of a particular trajectory shape.
Regarding mechanism innovation, this study integrates the
TRIZ method problem-solving approach to avoid being
limited to regularization thinking of mechanism theory to
overcome the technical contradiction problems by using
innovative methods, to quickly find the most appropriate
countermeasures, as well as to avoid consuming too much
time. Furthermore, in terms of dimension synthesis, the use
of the vector loop and Dyad analysis theory, along with the
movement trajectory and pedal angle constraints, helps us
obtain the desired results through relatively simple
calculations without adjuvant iterative calculations or the
assistance of computer programs. This process simplifies
the study procedures and shortens the study schedule.
Finally, this study not only presents theoretical research
results, but also carries out prototype production to verify
the feasibility of the study results. Regardless of the
features of use or tests of the main specifications, the
prototype meets the defined design goals.

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