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

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

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

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

Step 4/31

You can connect the NEURO MATIC system knee joint with a NEURO SWING, a NEURO VARIO-SWING or a NEURO VARIO-SPRING system ankle joint. To do so, insert the cable cover into the adaptor screw. Then, place both retaining washers into the adaptor screw and press them in with pliers.

Step 5/31

Determine the angle between tibial shell and foot piece.
NEURO SWING and NEURO VARIO-SWING:
If you are using a NEURO SWING or a NEURO VARIO-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

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 and NEURO VARIO-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

The cable cover exceeds the edge of the orthosis. Flush-cut the cable cover with a sharp knife.
NEURO SWING and NEURO VARIO-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

Degrease and roughen the end of the wire. Set a drop of low-viscous fast-acting adhesive 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 let the fast-acting adhesive harden.
Note: Mind the safety data sheet when using fast-acting adhesive.

Step 9/31

The wire must not have any room to move downwards as it is exposed to shear load. This way, you can avoid that the adhesive comes off and the wire slides downwards. The wire would then be too short at the top and the system joint could not lock.

Step 10/31

NEURO SWING and NEURO VARIO-SWING:
Slide the pressure spring over the wire onto the pin. Guide the pin with pressure spring and wire through the adaptor screw 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 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

Guide the cable cover with wire through the cable cover conduit again.
NEURO SWING and NEURO VARIO-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

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

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

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

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

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

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

Step 18/31

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

Mount the joint's upper part and, afterwards, the cover plate. To do so, you need to guide the wire carefully from below through the cable cover at 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

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

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

Step 22/31

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, it does not affect the joint’s load capacity.

Step 23/31

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

Check if the system joint moves freely. Bring the system joint in extension. In order to check the flexion, hold the orthosis in a horizontal position and then let go of the femoral shell. The femoral shell should smoothly fall downward up to the maximum possible flexion grade. If the system joint does not move freely, mount the next thinner sliding washer, repeat all steps from step 15 onwards and check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Step 25/31

Check if the system joint moves without lateral play. Hold the tibial shell and try to move the femoral shell in varus-valgus. 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 washer and repeat all steps from step 15 onwards. Check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Step 26/31

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 joint assembly 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

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. Shorten the wire accordingly.

Step 28/31

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 delivered second wire and repeat all steps starting at the 8th. Check again.

Step 29/31

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 strength.

Step 30/31

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

Step 31/31

Press the extension stop damper into the intended bore. Make sure that the system knee joint can easily reach the extension stop via the step lock gearing.