Processing a Pulling Cable

Processing a Pulling Cable

with Pulling Cable Adaptor and Cable Cover

Orthoses with a locked system knee joint are equipped with a pulling cable for the patient to be able to unlock the orthosis in an easy and comfortable way. 

The following tutorial shows how a KAFO with a NEURO FLEX MAX system knee joint is equipped with a unilateral pulling cable. If you produce a bilateral orthosis, you can proceed the same way but simply skip the loop and direct the pulling cable from one pulling cable adaptor to the other instead. Or, if you are not embedding the pulling cable into the laminate, you can use the delivered coupler for the separable pulling cable in order to easily adjust the pulling cable’s length. 

You will find further information on the pulling cable in the respective manual: Pulling Cables.

 Preparing the Cable Conduit

Step 1/6

In order to equip a locked system knee joint with a pulling cable, begin by preparing the cable cover. To do so, insulate the cable cover with insulating wax to prevent resin from entering it when laminating the orthosis. The cable cover serves as conduit for the pulling cable in the final orthosis. It is placed before the final reinforcement layer is attached and before the orthosis is laminated.

Step 2/6

Consider the course of the cable cover when placing it. The cable conduit should be placed within the radius of the locking pawl (green) for the pulling cable to meet the locking pawl from above and the system joint to unlock smoothly.

Step 3/6

The cable cover should end beside the locking pawl, within the area of the pulling cable adaptor (green), which is mounted later on, for the pulling cable to meet the adaptor the best possible way.

Step 4/6

Place the cable cover anteriorly along the system string. It should end as high as possible in order to enable an optimum force transmission. Secure the cable cover with unidirectional carbon fibre band.

Step 5/6

Keep on reinforcing as usual and attach the final reinforcement layer afterwards. By doing so, you secure the cable cover as well.
Continue to laminate, cut, temper and grind the orthosis.

Step 6/6

In order for the laminated cable cover to be used as a cable conduit for the pulling cable, you have to remove the insulating wax. Open both ends of the cable conduit with a suitable tool. Heat the wax residues with a hot air blower and blow the liquefied insulating wax out of the conduit.
Important! Do not heat to temperatures above 140°C (284°F) in order to avoid damages to the laminate.

 Mounting the System Joints

Step 1/1

Mount the system joints according to the assembly instruction in the manual of each respective system joint.
Note: you can also find manuals in the download section.

 Mounting the Pulling Cable

Step 1/6

Mount the pulling cable adaptor according to the assembly instruction in the manual of each respective system joint.
Note: you can also find manuals in the download section.

Step 2/6

Secure the threaded sleeve with a suitable tool (e.g. needle-nose pliers) on the pulling cable. As the threaded sleeve is cone-shaped, make sure that you mount it in such a way that it can be inserted into the pulling cable adaptor later on.

Step 3/6

Push the pulling cable from below through the opening of the pulling cable adaptor into the cable conduit until the threaded sleeve is flush with the pulling cable adaptor and is no longer visible.

Step 4/6

If you cannot pull the threaded sleeve into the pulling cable adaptor, either the threaded sleeve or the pulling cable adaptor have been attached the wrong way around. Secure the threaded sleeve the other way around on the pulling cable or turn the pulling cable adaptor. Then, push the pulling cable through the adaptor into the cable conduit again.

Step 5/6

Pull the ferrule over the upper end of the pulling cable and insert this end into the ferrule’s second opening to form a loop. Adjust the pulling cable length and the loop's size to your patient’s needs. Flush-cut the exceeding pulling cable. Finally, secure the ferrule with centre-punch marks on the the pulling cable.

Step 6/6

This is how the pulling loop of an orthosis with unilateral pulling cable looks like.