Ankle Assembly

Ankle Joint Assembly

Table of Contents

Step 1 – Let’s first assemble stage 1 input pulley

Step 2 – Let’s assemble stage 2 input pulley

Step 3 – Let’s assemble stage 2 output pulley

Step 4 – Let’s combine step 3 with the ankle base

Step 5 – Let’s combine step 4 with the shaft ankle joint

Step 6 – Let’s assemble all the steps from 1-5 with the housing

Step 7 – Let’s close the housing

Step 8 – Let’s add the shafts and the shaft caps 

Step 9 – Let’s add the adjustable tube to the ankle

Step 10 – Finally let’s add the motor and the base

Coloring and Naming Convention

Orange text: parts are preassembled together

Red text: parts make up thrust bearing assembly

Will Be Added’s: These materials/tools will be added during the first few months of 2019

Parts starting with p_: These are custom manufactured parts that you have received

*Materials in the pictures are listed from top to bottom and then left to right.

*Tools in the pictures are listed from left to right.


Step 1: Let’s first assemble stage 1 input pulley

Materials:

(*Materials in the pictures are listed from top to bottom and then left to right.)

1 x p2001_stage1InputPulley_3mm_17teeth_sdpsi_A 6A52M017GT13
1 x p2004_pulleyFlange_stage1InputLarge
1 x 316 Stainless Steel Hex Drive Flat Head Screw (vendor: McMaster, part no: 93395A207)
1 x p2003_pulleyFlange_stage1InputSmall
2 x Stainless Steel Ball Bearing (vendor: McMaster, part no: 7804K117)
1 x p2002_motorCouplingAnkle

Tools:

(*Tools in the pictures are listed from left to right.)

1 x 2 mm Allen

Assembly Video:


Step 2 – Let’s assemble stage 2 input pulley

Materials:

(*Materials in the pictures are listed from top to bottom and then left to right.)

1 x p2005_stage2InputPulley_3mm_17teeth_sdpsi_A 6A52M017GT13
1 x Needle-Roller Bearing (vendor: McMaster, part no: 5905K210)
1 x Metric Steel Woodruff Key (vendor: McMaster, part no: 98490A160)
1 x p2007_pulleyFlange_stage2Input
1 x p2006_stage1OutputPulley_3mm_60teeth_sdpsi_A 6A52M060GT20

Tools:

N/A

Assembly Video:


Step 3 : Let’s assemble stage 2 output pulley

Materials:

(*Materials in the pictures are listed from top to bottom and then left to right.)

(2 x Unused Flanges Shown In Central Left)

1steelShaft, 0.25” Diameter, 1.54” Long (vendor: misumi, part no: U-SFR0.25-L1.54)
2 x iglide® G300, thrust washer  (vendor: Igus, part no: GTM-0713-005)
2 x p2010_shaftCover
2 x Black-Oxide Alloy Steel Hex Drive Flat Head Screw (vendor: McMaster, part no: 91294A002)
2 x Needle-Roller Bearing (vendor: McMaster, part no: 5905K210)
1 x p2008_stage2OutputPulley_3mm_60teeth_sdpsi_A 6A52M060GT20
1 x 3 mm (GT3) Pitch, 72 Teeth, 15mm wide Single Sided Neoprene Belt (vendor: SDP/SI, part no: A36R53M072150)
1 x p2009_linkageCoupler

Tools:

(*Tools in the pictures are listed from left to right.)

1 x 1.3 mm Allen
1 x Any Flat Head Screwdriver

Assembly Video:


Step 4 – Let’s combine step 3 with the ankle base

Materials:

(*Materials in the pictures are listed from top to bottom and then left to right.)

2 x Black-Oxide Alloy Steel Hex Drive Flat Head Screw (vendor: McMaster, part no: 91294A002)
1steelShaft, 0.25” Diameter, 1.22” Long (vendor: misumi, part no: U-SFR0.25-L1.22)
2 x iglide® G300, thrust washer  (vendor: Igus, part no: GTM-0713-005)
2 x p2010_shaftCover
1 x Step 3 Subassembly
1 x p2015_ankleBase
1 x Needle-Roller Bearing (vendor: McMaster, part no: 5905K210)

Tools:

(*Tools in the pictures are listed from left to right.)

1 x Any Flat Head Screwdriver
1 x 1.3 mm Allen

Assembly Video:


Step 5 – Let’s combine step 4 with the shaft ankle joint

Materials:

(*Materials in the pictures are listed from top to bottom and then left to right.)

1 x Step 4 Subassembly
1 x p2016_shaftSupport
2 x Needle-Roller Bearing (vendor: McMaster, part no: 5905K210)
1 x p2010_shaftCover
1 x Black-Oxide Alloy Steel Hex Drive Flat Head Screw (vendor: McMaster, part no: 91294A002)
2 x iglide® G300, thrust washer  (vendor: Igus, part no: GTM-0713-005)
1 x p2017_shaftAnkleJoint
1 x Magnet Note: Magnet already comes with the jointEncoder (vendor: Dephy, part no: AK7452_0_1B)

Tools:

(*Tools in the pictures are listed from left to right.)

1 x 1.3 mm Allen
1 x Any Flat Head Screwdriver

Assembly Video:


Step 6 – Let’s assemble all the steps from 1-5 with the housing

Materials:

(*Materials in the pictures are listed from top to bottom and then left to right.)

1 x Step 5 Subassembly
1 x 3 mm (GT3) Pitch, 72 Teeth, 9mm wide Single Sided Neoprene Belt (vendor: SDP/SI, part no: A36R53M072090)
1 x Step 1 Subassembly
1 x p2007_pulleyFlange_stage2Input
2 x 1 mm Thick Washer for 12 mm Shaft Diameter Needle-Roller Thrust Bearing (vendor: McMaster, part no: 5909K720)
1 x Needle-Roller Thrust Bearing (vendor: McMaster, part no: 5909K120)
1 x 18-8 Stainless Steel Socket Head Screw (vendor: McMaster, part no: 91292A124)
1 x Step 2 subassembly
1 x p2013_housingAnkle

Tools:

(*Tools in the pictures are listed from left to right.)

1 x 4 mm T Handle Allen
2 x Any T Handle Allen

Assembly Video:


Step 7 – Let’s close the housing

Materials:

(*Materials in the pictures are listed from top to bottom and then left to right.)

2 x 1 mm Thick Washer for 12 mm Shaft Diameter Needle-Roller Thrust Bearing (vendor: McMaster, part no: 5909K720)
1 x Needle-Roller Thrust Bearing (vendor: McMaster, part no: 5909K120)
1 x p2003_pulleyFlange_stage1InputSmall
1 x Stainless Steel Ball Bearing (vendor: McMaster, part no: 7804K117)
1 x Step 6 Subassembly
1 x p2013_housingAnkle

Tools:

N/A

Assembly Video:


Step 8 – Let’s add the shafts and the shaft caps

Materials:

*Materials in the pictures are listed from top to bottom and then left to right.

1steelShaft, 0.25” Diameter, 1.93” Long (vendor: Misumi, part no: U-SFR0.25-L1.93)
1steelShaft, 0.25” Diameter, 2.48” Long (vendor: Misumi, part no: U-SFR0.25-L2.48)
8m2.5_4mm_flat (vendor: McMaster, part no: 93395A172)
4p0003_shaftCap 

Note: Regarding the shaft caps, I used type A1 and B1 shaft caps. You can also use A2 with B2 or A3 with B3 depending on how tight you want the belts to be.

Tools:

(*Tools in the pictures are listed from left to right.)

1 x 1.5 mm Allen
1 x Any Flat Head Screwdriver

Assembly Video:


Step 9 – Let’s add the adjustable tube to the ankle

Materials:

*Materials in the pictures are listed from top to bottom and then left to right.

1 x Step 8 Subassembly
1 x p0002_pyramid
1 x p2011_proxBase
(Screws Will Be Added)
4 x 18-8 Stainless Steel Low-Profile Socket Head Screws (vendor: McMaster, part no: 92855A307)
1 x Pylon

Tools:

(*Tools in the pictures are listed from left to right.)

1 x 2 mm Allen
(Allen Will Be Added)
(T Handle Allen Will Be Added)

Assembly Video:


Step 10 – Finally let’s add the motor and the base

Materials:

*Materials in the pictures are listed from top to bottom and then left to right.

1 x Step 9 Subassembly
1 x Dephy Actuator (contact Dephy from Link )
1 x lowProfileVariFlexFoot (vendor: Ossur, Part No: VLPE5250 (size 25) or VLPE5270 (size 27) or VLPE5290 (size 29))
2 x M8_washer (vendor: McMaster, part no: 90965A190)
2 x M8_16mm_socket  (vendor: McMaster, part no: 96144A216)
1 x M5_10mm_socket (vendor: McMaster, part no: 91292A124)
4 x M3_16mm_standoff (vendor: McMaster, part no: 98952A043)
4 x M3_10mm_low (vendor: McMaster, part no: 92855A310)
4 x M2_4mm_flat (vendor: McMaster, part no: 93395A136)

Tools:

(*Tools in the pictures are listed from left to right.)

1 x 6mm L Shape Allen
1 x 2mm Allen
1 x 1.5mm Allen
(1 x Unused Allen Shown)
1 x 4mm T Handle Allen

Assembly Video: