Joint Assembly

NEURO TRONIC System Knee Joint

The NEURO TRONIC system knee joint is an automatic joint which is electromechanically locked and unlocked. The system joint is controlled by motion sensors integrated in the controller of the orthosis. For this purpose, a placeholder for the corresponding system components is used when producing the orthosis. For more information, see the online tutorial Lamination Dummies NEURO MATIC/NEURO TRONIC. Updates for the NEURO TRONIC knee joint system are made available here on a regular basis. Sign up for our newsletter EXPERTMAIL to be informed about innovations.

 Joint Assembly NEURO TRONIC

Step 1/34

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 2/34

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 3/34

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

Step 4/34

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 5/34

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 6/34

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

Step 7/34

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.

Step 8/34

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

Step 9/34

Place the second sliding washer on the bearing nut while fixing the bearing nut from the backside with one finger. Mount the joint’s upper part with the toothed ring.

Step 10/34

Mount the cover plate without the solenoid and tighten the screws with the corresponding torque.
Note: You will find information about the torque in the manual of the corresponding system joint.

Step 11/34

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 12/34

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 13/34

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 washers, repeat all steps from step 8 onwards and check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Step 14/34

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 has lateral play, mount the next thicker sliding washers, repeat all steps from step 8 onwards and check again.
Note: At a bilateral orthosis, only check one system joint at a time.

Step 15/34

Check the mobility of the locking pawl. To do so, set the lever to the dot. 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 the dot.

Step 16/34

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 17/34

Mount the solenoid. Place the pressure spring and then the washer onto the plunger. Put the plunger with pressure spring and washer in the solenoid and mount the solenoid into the cover plate.

Step 18/34

Connect the connector of the solenoid cable with the solenoid. It does not matter to which pole of the solenoid the cable is connected. Afterwards, place the solenoid with connector in the big cover plate.

Step 19/34

Mount the small cover plate and fix it by tightening the screw.

Step 20/34

Press the extension stop damper into the predetermined bore.

Step 21/34

Prepare the retainer for the controller. To do so, cut in the pre-milled grooves with a knife. Break out the piece and smooth the edges with sandpaper.

Step 22/34

Apply CA-Activator Spray to the lower surface of the retainer for the controller and allow it to flash off briefly. Adhere the retainer for the controller to the tibial shell of the orthosis by using a small amount of fast-acting adhesive.
Note: Mind the safety data sheet when using the fast-acting adhesive.

Step 23/34

Please note that the cable dummy determines the route of the cable and, thus, depending on the route, the length of the cable varies.

Step 24/34

Place the solenoid cable in the depression created by the cable dummy until it reaches the retainer for the controller. On the cable, mark the position of the opening through which the cable is led into the retainer for the controller. This marking indicates the length of the cable sheathed in black.

Step 25/34

Make a second marking at a distance of 5 to 7 cm from the first marking in the direction of the end of the cable. This marking indicates the length of the entire cable. Cut the cable at this marking with pliers. Then, you need to strip the cable up to the first marking. Use the FIOR & GENTZ stripping tool.

Step 26/34

You can now see two exposed cable wires. Strip the ends of the cable wires again. Then, you need to twist and tin the braids.

Step 27/34

Adhere the cable to the tibial shell of the orthosis by using a small amount of fast-acting adhesive. Start close to the system joint and work your way up to the retainer for the controller.
Note: Mind the safety data sheet when using the fast-acting adhesive.

Step 28/34

Establish a cable connection to the controller. On a controller with exchangeable batteries, the four connections are marked with numbers from 1 to 4. Put the braids into the cable connections 3 and 4. It does not matter to which pole the cables of the solenoid are connected.
Note: For a bilateral construction with two NEURO TRONIC system knee joints, two cable wires are each plugged into the cable connections 3 and 4.

Step 29/34

On a controller with integrated lithium-ion battery, the numbers can be found on the cable connecting aid. Put the braids into the cable connections 3 and 4 with the aid of the cable connecting aid. It does not matter to which pole the cables of the solenoid are connected.
Note: For a bilateral construction with two NEURO TRONIC system knee joints, two cable wires are each plugged into the cable connections 3 and 4.

Step 30/34

Then, you need to place the controller into the retainer for the controller.

Step 31/34

Secure the controller by tightening the four screws of the retainer for the controller.

Step 32/34

If you have a controller with exchangeable batteries without Bluetooth, place the supplied batteries in the battery compartment of the controller according to the plus and minus poles and press the MODE button (e.g. with a paper clip). The LEDs will then blink. This indicates that you can now connect the controller with the multi-purpose device within 30 seconds. Slide the lid onto the controller to close the battery compartment.

Step 33/34

If you have a controller with exchangeable batteries with Bluetooth, place the supplied batteries in the battery compartment of the controller according to the plus and minus poles and press the MODE button (e.g. with a paper clip). A short beep is emitted. Keep the button pressed until a second, longer beep is emitted after about 6-10 seconds. This indicates that you can now connect the controller with the multi-purpose device or the patient remote control within 30 seconds. Slide the lid onto the controller to close the battery compartment.

Step 34/34

If you have a controller with integrated lithium-ion battery, press the MODE button. A short beep is emitted. Keep the button pressed until a second, longer beep is emitted after about 6-10 seconds. This indicates that you can now connect the controller with the multi-purpose device or the patient remote control within 30 seconds. To finish, slide the cover over the Micro-USB port.