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i-digits™ Component Assembly Guide

Part number MA01349, Revision no.3 : February 2016

2 of 25 Part number MA01349, Revision no.3 : February 2016

This symbol signifies important information and is used throughout the manual.

This document provides instruction for prosthetists in the assembly of i-digits™ components necessary for the fabrication of i-digits™ prostheses. The instructions within should be read in full prior to fabrication. It is highly recommended that the use of this manual is made in conjunction with instruction from a clinician experienced in the use of i-digits™.

Refer to http://www.touchbionics.com/downloads/document-library to ensure you have the latest copy of this document.

Table of Contents

1. Wristband, Dummy Positioning and Digit Assembly 1.1 Positioning of the Socket Terminal Dummy 3 1.2 Removal of the Digit from the Knuckle 4 1.3 Extra Small and Medium Digit Assembly 4 1.4 Knuckle Mounting Plate 5 1.5 Attachment of the Knuckle Mounting Plate 6 1.6 Attachment of the Digit to the Knuckle Assembly 6

2. Transfer of Alignment 2.1 Thumb Alignment 7 2.2 Knuckle Dummies 7 2.3 LP Remote Electrode Domes 8 2.4 Check Suspension 9 2.5 Knuckle Fairing Options 10 3. Assembly 3.1 Thumb Rotator Assembly – Setting and Assembly 11 3.2 Attaching the Thumb 12 3.3 Wristband Wiring Connections 13 3.4 Connecting the Digits to the Wristband 15 3.5 Removing the Digit Wires 17 3.6 Connecting the Electrodes to the Wristband 18 3.7 Removing the Electrode Cables 20 3.8 Completing the Wristband Assembly 21

4. Digit Covers 4.1 Attaching the Digit Cover 24

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1.0 Wristband, Dummy Positioning and Digit Assembly

1.1 Positioning of the Socket Terminal Dummy

Place the Socket Terminal Dummy on the Dorsal surface of the positive cast (fig.1). The position should be central to the midline of the wrist and elbow joints. A distance of 30mm should be left between the Socket Terminal Dummy and the center of the wrist joint to enable good range of movement at the wrist (fig.2).

Final position of Wristband

Midline

Figure 2

Figure 1

Figure 3

30mm


1.2 Removal of the Digit from the Knuckle

Use the T6 Screwdriver to remove the M3 Grub Screw from the Knuckle Assembly (fig.4).

The digit can now be freely disengaged from the Knuckle Assembly.

Figure 4

Figure 5

Figure 6

1.3 Extra Small and Medium Digit Assembly

Depending on the size of the kit, the Knuckle Mounting Plate will vary in shape.

Figure 5 shows a Medium Digits Assembly.

Figure 6 shows an Extra Small Digit Assembly.


1.4 Knuckle Mounting Plate

The Knuckle Mounting Plate will support 4 digits.

This Mounting Plate can be cut to suit the number of digits required for the user, fig.7.

Knuckle Mounting Plate

Modified Knuckle Mounting Plate

Figure 7


1.5 Attachment of the Knuckle Mounting Plate

Use the T6 Screwdriver to attach the Knuckle Assembly to a Multiple Knuckle Mounting Plate using three M2 x 6mm Torx Screws.

Lamination tabs can be bent or shortened as appropriate.

Consider fabrication before cutting and removing tabs, since some tab length will be needed for fixation of the plate to the frame (fig.8).

1.6 Attachment of the Digit to the Knuckle Assembly

Firmly place the digit into the Knuckle Assembly.

Figure 8

Figure 12

Take care not to over tighten screws.

Screws supplied are recommended for single use only. Always use new screws for final assembly.


Figure 9

Insert the M3 grub Screw using the T6 torque driver provided, set to 1.0Nm (fig.9).

Pre-flex the digit slightly to aid the attachment of the digit.


2.2 Knuckle Dummies

Single knuckle dummies are used to aid transfer of alignment. Attach the Single Knuckle Dummies to the Knuckle Mounting Plate using three M2 x 16mm Countersunk Torx Screw and the T6 Screwdriver (fig.12).

Figure 10

2.0 Transfer of Alignment

2.1 Thumb Alignment

The use of the Thumb Alignment Plate is to aid the position of the Thumb Mounting Plate (fig.10).

Screw the thumb alignment plate onto the Knuckle Mounting Plate using three M2x5mm screws.

Depending on the handedness, attach the thumb rotation assembly to the correct side of the alignment plate, fig.11, using three M2x5mm screws.

Figure 10

Left hand

Right hand

Figure 11

Figure 12


Insert the Alignment Bars into the Single Knuckle Dummies and lock each in place using M2 x 5mm Countersunk Torx Screw and the T6 Screwdriver (fig.13).

Figure 13

The electrode domes will be assembled into the silicone using the parts shown in figure 14.

Figure 14

Lamination Dome Dummy

Silicone Dome Dummy

Single SuspensionDouble Suspension

2.3 LP Remote Electrode Domes


2.4 Check Suspension

During the check socket process, the single (fig.16) and double check suspension (fig.17) should be used.

Figure 16

Figure 17

Figure 15 Figure 15 shows how the dome will look once fabricated

into the silicone.


Figure 19

Components for direct lamination are shown in figure 18.

Components for non-laminated fairings are shown in figure 19.

Figure 18

Fairing

Knuckle Dummy

2.5 Knuckle Fairing Options


3.1 Thumb Rotator Assembly – Setting and Assembly

The full thumb rotator assembly is illustrated (fig.20). To increase the force required to rotate the thumb, remove the Nut Cap and use the 8mm Spanner to tighten the M4 Locking Nut. The grub screw will need to be loosened to tighten the nut.

Ensure the Clutch Plate is not contaminated, as this will affect performance.

Figure 21

Figure 20

Clutch Plate

3.0 Assembly

Hand tighten with fingers and then turn a further 120 to 150° to give the desired thumb friction depending on patient preferences (fig.21), using the 8mm Spanner. The wire will now travel down through the centre of the spigot.

Attach each digit using the supplied screws. Screws are recommended to be single use.


3.2 Attaching the Thumb

Remove the base cap on the thumb rotator assembly by removing the two M2x5mm Screws, fig. 22

Remove the knuckle cover from the thumb assembly by removing the two M2x4mm Screws, fig.23.

Remove the knuckle assembly from the thumb assembly by removing the M3 Grub Screw, fig 24.

Screw the knuckle onto the thumb rotator assembly using 3 M2x5mm Screws, fig.25.

Using a torque driver set to 1Nm, re-attach the thumb to the single knuckle assembly, fig.26.

Slide the knuckle fairing over the back of the thumb and attach using two M2x5mm Screws, fig.27.

Finally, re-attach the base cap, using the screws previously removed fig.28.

Figure 28Figure 27

Figure 24

Figure 23Figure 22

Figure 26

When inserting the M3 grub Screw into the single knuckle a T6 torque driver, set to 1.0Nm , must be used(fig.26).

Figure 25



Figure 31Strip the digit wire insulation back by 3.5 to 4.5mm, fig.31. Before wire insertion the stranded wires should be tightly bunched and twisted clockwise, fig.32.

3.5-4.5mm

Figure 32

Remove the bellows by pulling them over the socket end of the assembly, as shown, to expose the PCB, fig.29. Figure 29

Figure 30

Take care not to damage the PCB

Slide the protective PCB cover out of the bellows assembly, fig .30.

3.3 Wristband Wiring Connections


Slide the digit wires through the left hand aperture at the front of the bellows assembly, fig.33 & 34. Figure 33

Figure 34


Connecting the Digits to the Wristband

All the digit wires will be supplied in pairs, with each pair coming from a different digit.

If a thumb is present connect the thumb wires to the two way connector as shown in, fig.36.

Push the stripped wire fully home into the connectors.

Next connect all the remaining digit wires, following the mapping set up in, fig.35.

Figure 37 shows all of the digit wires connected.

Figure 37

Thumb

IndexMiddleRingLittle

Figure 35

Figure 36

3.4

Incorrect positioning of wires could result in irreversible damage to the PCB.


Create slack in the digit wires as shown in fig.38, so that the bellow assembly flexes without tension in the digit wires , fig.39. Figure 38

Figure 39

Figure 40

If there is too much slack, as shown in fig,41, it may be difficult to complete the assembly of the bellows. Figure 41

If there is not enough slack, as shown in fig,40, flexing of the bellows may lead to failure of the digit wire connection.


Figure 42

Figure 43

Before re-insertion, the wire must always be re-stripped and twisted.

To remove the digit wire, gently rotate the wires clockwise while pulling out of the connector, fig.42 & 43. Use thin nosed pliers if required.

Check the connectors for broken wire strands after taking the wire out and remove if required.

Push the stripped wire fully home into the connectors.

Strip the digit wire insulation back by 3.5 to 4.5mm, fig.31. Before wire insertion the stranded wires should be tightly bunched and twisted clockwise, fig.32.

3.5 Removing the Digit Wires


Figure 46

Once the digit wires are connected, slide the electrode cables through the right hand aperture shown in figure 45.

Connect the cables following the mapping shown in figure 44.

To mate the connectors, the mating axes of both connectors must be aligned and then the connectors can be mated. The “click” will confirm fully mated connection.

(Digit wires not shown for clarity)

Take care not to damage the PCB.

Figure 44

Signal 1

Ground

Signal 2

Connecting the Electrodes to the Wristband.

Do not attempt to insert on an extreme angle or the connector will break.

3.6

Figure 45

Figure 46 shows all of the cables connected.


Create slack in the cables, fig.47, (similar to the digit wires shown in fig. 38.) Figure 47

The signal cables inserted in signal 1 position should be routed as shown in figure 48. Figure 48

Check that there is no tension in the cables when flexed as shown in figure 49. Figure 49

Before completion of the next stage, check that digits and electrodes are all functioning correctly.


If the electrode cables need to be repositioned, use the extraction tool supplied, fig.50.

Insert the end portion of the tool under the connector flanges and pull off vertically, in the direction of the connector mating axis, fig.51 & 52.

Figure 52

Figure 51

Figure 50

Pull the connector up vertically with the removal tool or the connector will be damaged.

3.7 Removing the Electrode Cables


Trim the PCB protector by removing the tab, fig.54 , approximately 2.5mm, with a knife or scissors. Figure 54

Figure 53Bond the electrode cables into the right hand aperture using silicone provided, fig.53.

Silicone

3.8 Completing the Wristband Assembly

Fit PCB protector over Bellows PCB.

Apply reinforcement tape of type:

25mm x 50m X/Weave Filament Tape, widely available e.g. from Limbtex

Cut the tape to an approximate length of 80mm then slide the tape underneath the PCB and wire assembly, fig.55.

Figure 55

Taking care not to strain the digit wire and cable connections at the Bellows PCB, fold over the tape and press together, fig 56. Figure 56


Carefully, unplug the PCB from the wristband assembly. Remove the two M2.5 Screws from the underside of the wristband and remove the bellows assembly, fig.57.

Figure 58Slide the bellows back on as shown in figure 58 and bond with silicone adhesive.

Figure 57


Reattach the bellows by pushing the connector from the bellows into the connector from the wristband and insert the two M2.5 screws, fig.59.

Figure 59

Attach the wristband to the socket using the M4 Socket Button Head Screw, fig.60 and 61.

Figure 60

Figure 61


Figure 62

Figure 63

4.0 Digit Covers

4.1 Attaching the Digit Covers

Each digit must use a digit cover. These covers simply slide on over the digit, fig.62 & 63.

This also applies for the thumb cover, fig.64 & 65.

Figure 65Figure 64

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North America(Canada, Mexico & US)

Touch Bionics35 Hampden Road

Mansfield MA 02048USA

Tel: +1 855 MY iLIMB (694 5462)

Germany/ FranceTouch Bionics GmbH

Langer Anger 369115 Heidelberg

Germany Tel: : +49 6221 357 9060

InternationalTouch Bionics

Unit 3, Ashwood CourtOakbank Park Way

Livingston EH53 0THScotland

Tel: +44 1506 438 556Email: [email protected]

For address details and further information please visit www.touchbionics.com

Third party products and brand names may be trademarks or registered

trademarks of their respective owners

© Copyright 2015 Touch Bionics Inc. and Touch Bionics Limited. All rights reserved.

February 2016 Part number: : MA01349 revision no. 3

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