Joint Assembly NEURO MATIC

Joint Assembly

NEURO MATIC System Knee Joint

The NEURO MATIC system knee joint is an automatic joint. By connecting system knee joint and system ankle joint, the NEURO MATIC system knee joint locks and unlocks mechanically. The NEURO SWING, the NEURO VARIO-SWING or the NEURO VARIO-SPRING system ankle joint can be used for the ankle area. This online tutorial contains all options. To choose the most suitable system ankle joint, we recommend using the Orthosis Configurator.

Furthermore, the NEURO MATIC system knee joint can be converted into a NEURO TRONIC system knee joint, if necessary. For this purpose, refer to the online tutorial NEURO TRONIC in e-Motion.

Joint Assembly NEURO MATIC

Step 1/31

Joint Assembly NEURO MATIC

Clean the system joint. In order to clean the threads in the cover plate, use the Super Clean LOCTITE® 7063 to remove any insulating wax residues.
Note: Mind the safety data sheet when using the Super Clean LOCTITE® 7063.

Step 2/31

Joint Assembly NEURO MATIC

Apply spray adhesive to one side of the first sliding washer and adhere it to the big cover plate. Grease the other side of the sliding washer slightly with the delivered orthosis joint grease.

Step 3/31

Joint Assembly NEURO MATIC

Mount the toothed ring with sliding bushing to the joint's upper part.

Step 4/31

Joint Assembly NEURO MATIC

Screw the cable cover as far as possible (about 5mm) into an adaptor screw with knurl that corresponds to the system ankle joint.

Step 5/31

Joint Assembly NEURO MATIC

Determine the angle between tibial shell and foot piece.
NEURO SWING: If you are using a NEURO SWING system ankle joint, you need to mount the system ankle joint with spring units. Mount the dorsal spring unit without the alignment screw.
NEURO VARIO-SPRING: If you are using a NEURO VARIO-SPRING system ankle joint, you first need to mount the adaptor screw to the cover plate.

Step 6/31

Joint Assembly NEURO MATIC

Mount the cable cover. To do so, you need to guide the cable cover through the cable cover guidance of the tibial shell into the cable cover conduit.
NEURO SWING: Screw the adaptor screw into the screw unit of the dorsal spring unit.
NEURO VARIO-SPRING: Mount the cover plate of the system ankle joint to the joint's upper part.

Step 7/31

Joint Assembly NEURO MATIC

The cable cover exceeds the edge of the orthosis. Flush-cut the cable cover with a sharp knife.
NEURO SWING: Demount the adaptor screw and pull the cable cover out of the cable cover conduit.
NEURO VARIO-SPRING: Demount the cover plate of the system ankle joint and pull the cable cover out of the cable cover conduit.

Step 8/31

Joint Assembly NEURO MATIC

Degrease and roughen the end of the wire.
NEURO SWING/NEURO VARIO-SPRING: Set a drop of fast-acting adhesive with low viscosity on the bore of the pin. Guide the wire through the bore into the pin. Quickly move the wire up and down several times to spread the fast-acting adhesive evenly and to remove air from the bore. Insert the wire into the bore so that no space is left at the bottom and wait for the fast-acting adhesive to harden.
Note: Mind the safety data sheet when using fast-acting adhesive.

Step 9/31

Joint Assembly NEURO MATIC

The wire must not have any room to slide downwards as it is exposed to shear load. That way, the adhesive will not come off and the wire will not slide downwards. Thus, the wire being too short at the top will be prevented and the joint will still be able to lock.

Step 10/31

Joint Assembly NEURO MATIC

NEURO SWING: Slide the pressure spring over the wire onto the pin. Guide the pin with pressure spring and wire through the adaptor screw with knurl into the cable cover.
NEURO VARIO-SPRING: Slide the pressure spring over the wire onto the pin. Guide the pin with pressure spring and wire through the adaptor screw with knurl into the cable cover. Attach the adaptor screw to the cover plate by inserting the ball and then the pin with pressure spring and wire in the spring duct. To finish, you need to tighten the adaptor screw.

Step 11/31

Joint Assembly NEURO MATIC

Guide the cable cover with wire through the cable cover conduit again.
NEURO SWING: Screw the adaptor screw into the screw unit of the system ankle joints’ dorsal spring unit.
NEURO VARIO-SPRING: Mount the system ankle joint by using the assembly aid for cover plate.
Note: Please note that the angle between lower leg and foot piece determines the length of the wire. If this angle changes, the length of the wire will have to be adapted accordingly. In order to avoid this, you need to check the alignment of the orthosis before shortening the wire.

Step 12/31

Joint Assembly NEURO MATIC

The wire should be flush with the locking pawl of the NEURO MATIC system knee joint. Mark the crossing point of the wire and the locking pawl and cut the wire at the marking (lower edge of the locking pawl).

Step 13/31

Joint Assembly NEURO MATIC

Take a piece of cable cover. Slightly chamfer one end and screw it into the thread of the big cover plate of the NEURO MATIC system knee joint. By doing so, you will receive an ideal guidance for the wire. Afterwards, you need to shorten the other end with a sharp knife until the cable cover protrudes by 1-2cm.

Step 14/31

Joint Assembly NEURO MATIC

Grease the axle bore of the locking pawl and of the toothed ring as well as the friction surfaces of the bearing nut with the delivered orthosis joint grease.
Note: Make sure that no grease enters the toothing of the locking pawl and the toothed ring.

Step 15/31

Joint Assembly NEURO MATIC

Put the bearing nut for the locking pawl into the intended opening on the joint’s lower part. Ensure that the bearing nut is in the correct position. Mount the locking pawl.

Step 16/31

Joint Assembly NEURO MATIC

Grease the axle bore of the joint axis and the friction surfaces of the bearing nut with the delivered orthosis joint grease.

Step 17/31

Joint Assembly NEURO MATIC

Slightly grease the second sliding washer on both sides with the delivered orthosis joint grease.

Step 18/31

Joint Assembly NEURO MATIC

Put the bearing nut for the joint axis into the intended opening on the joint’s lower part. Ensure that the bearing nut is in the correct position. Place the second sliding washer on the bearing nut.

Step 19/31

Joint Assembly NEURO MATIC

Mount the joint's upper part. After that, the cover plate is mounted. To do so, you need to guide the wire carefully from below through the cable cover to the cover plate. Place the cover plate on the joint's upper part.
Note: The lever should be set to A (Auto).

Step 20/31

Joint Assembly NEURO MATIC

Tighten the screws with the corresponding torque.
Note: You will find information about the torque in the manual of the corresponding system joint.

Step 21/31

Joint Assembly NEURO MATIC

If you have damaged a sliding washer during the assembly of the cover plate (you would hear a soft cracking), remove the particles and place a new sliding washer.

Step 22/31

Joint Assembly NEURO MATIC

Make sure that the bearing nuts are placed completely in the intended openings. Note: The delivered screws are always matching the system joint. Even when the screws are not as long as the thread of the bearing nuts, the system joint’s load capacity is not affected.

Step 23/31

Joint Assembly NEURO MATIC

At a system joint with a system width of 16mm, the hardened laminate must be milled at the lever area in order to be able to set the lever to F (Free).
Note: During the following steps, the lever remains set to F.

Step 24/31

Joint Assembly NEURO MATIC

Check if the system joint moves freely. Bring the system joint in flexion/extension. If the system joint does not move freely (it jams), you need to mount the next thinner sliding washers and repeat all steps starting at the 16th. Check again.

Step 25/31

Joint Assembly NEURO MATIC

Check if the system joint moves without lateral play. Fix the tibial shell and move the femoral shell in varus-valgus direction. If the system joint moves with lateral play, make sure that the sliding bushing is mounted correctly. If there is lateral play, even though the sliding bushing is mounted correctly, you need to mount the next thicker sliding washers and repeat all steps starting at the 16th. Check again.

Step 26/31

Joint Assembly NEURO MATIC

Check the mobility of the locking pawl. Set the lever to A. Turn the orthosis until the foot piece points upwards. By doing so, the locking pawl falls into the toothing. Now, it should no longer be possible to flex the system knee joint. If the system knee joint can still be flexed, check the assembly of the joint and remove, if there are any, remaining resin residues and surplus grease from the system knee joint. Check again.
Note: During the following steps, the lever remains set to A.

Step 27/31

Joint Assembly NEURO MATIC

Control the length of the wire. To do so, put the orthosis in a shoe to which the orthosis is adjusted. Move the system ankle joint until the dorsiflexion stop is reached. In this position, you should be able to bring the system knee joint in extension/flexion. If this is not the case, the wire is too long. You need to shorten the wire accordingly.

Step 28/31

Joint Assembly NEURO MATIC

Bring the system ankle joint in plantar flexion. The locking pawl can now reach the locking position via the wire. Therefore, it should no longer be possible to flex the system knee joint. If this is still the case, the wire is too short. Replace the wire with the supplied second wire and repeat all steps starting at the 8th. Check again.

Step 29/31

Joint Assembly NEURO MATIC

Secure the axle screw and the screw of the locking pawl with LOCTITE® 243 medium strength and the corresponding torque. Let the adhesive harden (final strength after approx. 24 hours).
Note: Mind the safety data sheet when using LOCTITE® 243 medium streng.

Step 30/31

Joint Assembly NEURO MATIC

Mount the small cover plate by tightening the axle screw by hand.

Step 31/31

Joint Assembly NEURO MATIC

Press the extension stop damper into the pre-determined bore. Make sure that the system knee joint can reach the extension stop via the step lock gearing with ease.