Knee Assembly

Knee Joint Assembly

Table of Contents

Step 1 – Let’s assemble the stage 1 output pulley

Step 2 – Let’s place stage 1 output pulley and stage 2 input pulley into the housing

Step 3 – Let’s place stage 2 output pulley and stage 3 input pulley into the housing 

Step 4 – Let’s close the housing 

Step 5 – Let’s add the shafts and the shaft caps

Step 6 – Let’s add the angular contact bearings

Step 7 – Finally let’s add the motor

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 assemble the stage 1 output pulley

Materials:

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

1 x p1001_stage1InputPulley_2mm_16teeth
1 x p1002_motorBearingHousing
2 x stage1Belt_2mm_92teeth (vendor: sdpsi, part no: A36R51M092060)
2 x stage1Belt_2mm_92teeth (vendor: sdpsi, part no: A36R51M092090)
2 x p1005_pulleyFlange_stage1Input
2 x BallBearing (vendor: McMaster, part no: 7804K117)
2 x Tape Pieces (around 2.5cm)

Tools:

N/A

Assembly Video:


Step 2 – Let’s place stage 1 output pulley and stage 2 input pulley into the housing

Materials:

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

1 x p1019_housingKneeLeft
1 x p1008_pulleyFlange_stage2Input
1 x p1006_stage2InputPulley_5mm_14teeth_sdpsi_A 6A54M014GT18
1 x p1007_stage1OutputPulley_2mm_80teeth_sdpsi_A 6A50M080GT20
2 x Needle-Roller Bearing (vendor: McMaster, part no: 5905K210)
1 x p1003_motorPulleyLock
1 x Step 1 Subassembly
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)
3 x 316 Stainless Steel Hex Drive Flat Head Screw (vendor: McMaster, part no: 93395A198)
2 x 18-8 Stainless Steel Low-Profile Socket Head Screws (vendor: McMaster, part no: 92855A307)
1 x 18-8 Stainless Steel Low-Profile Socket Head Screws (vendor: McMaster, part no: 92855A413)

Tools:

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

1 x 2 mm Allen
1 x 2 mm T Handle Allen
1 x 2.5 mm T Handle Allen

Assembly Video:


Step 3 – Let’s place stage 2 output pulley and stage 3 input pulley into the housing

Materials:

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

1 x Step 2 Subassembly
1 x 5 mm (GT3) Pitch, 50 Teeth, 15mm wide Single Sided Neoprene Belt (vendor: SDP-SI, part no: A36R55M050150)
1 x p1009_stage3InputPulley_5mm_14teeth_sdpsi_A 6A54M014GT18
1 x p1010_stage2OutputPulley_5mm_40teeth_sdpsi_A 6A54M040GT20
2 x Needle-Roller Bearing (vendor: McMaster, part no: 5905K210)
1 x p1011_pulleyFlange_stage3Input
3 x 5 mm (GT3) Pitch, 60 Teeth, 15mm wide Single Sided Neoprene Belt (vendor: SDP-SI, part no: A36R55M060150)
1 x p1012_stage3OutputPulley_5mm_48teeth_sdpsi_A 6A54M048GT20
2 x p1101_gearStopNoSpring
1 x p1102_spacer
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)
12 x Alloy Steel Dowel Pin (vendor: McMaster, part no: 91595A143)

Tools:

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

(1 x Unused Allen Shown)
1 x Any Flat Head Screwdriver
1 x Any T Handle Allen

Assembly Video:


Step 4 – Let’s close the housing

Materials:

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

1 x M3_18mm_socket (vendor: McMaster, part no: 92290A761)
1 x p1018_housingKneeRight
1 x Step 3 Subassembly
1 x p1018_housingKneeRight
4 x 1 mm Thick Washer for 12 mm Shaft Diameter Needle-Roller Thrust Bearing (vendor: McMaster, part no: 5909K720)
2 x Needle-Roller Thrust Bearing (vendor: McMaster, part no: 5909K120)

Tools:

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

(Unused Screwdriver Shown)
1 x 2.5 mm Allen
1 x Any T Handle Allen

Assembly Video:


Step 5 – 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.)

1 x Step 4 Subassembly
2 x steelShaft_0.25in_3.03in (vendor: misumi, part no: U-SFR0.25-L3.03)
4 x p0003_shaftCap
(1 Unused Screw Shown)
4 x Tape Pieces (around 2.5cm)

Tools:

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

1 x Any Flat Head Screwdriver
(1 x Unused Allen Shown)
1 x 1.3 mm Allen

Assembly Video:


Step 6 – Let’s add the angular contact bearings

Materials:

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

1 x Step 5 Subassembly
2 x Thin-Section Ball Bearing – Angular Contact, 1.0000 in Bore, 1.3750 in OD, 0.1875 in Width, Open (vendor: Motion Industries, part no: KAA10AG0)
2 x p1014_proxPyramidStrut
4 x M3_18mm_socket (vendor: McMaster, part no: 92290A761)
2 x 316 Stainless Steel Hex Drive Flat Head Screw (vendor: McMaster, part no: 93395A304)
4 x 316 Stainless Steel Hex Drive Flat Head Screw (vendor: McMaster, part no: 93395A198)
1 x p1015_magnetHolder
1 x Will Be Added (Magnet – comes with the encoder (z_jointEncoder_dephy_AK7452_0_1B)?)
1 x p1013_proxPyramid
1 x p0002_pyramid
3 x M5_10mm_low (vendor: McMaster, part no: 93070A121))
4 x 18-8 Stainless Steel Low-Profile Socket Head Screws (vendor: McMaster, part no: 92855A307)
1 x p1016_distalBase
1 x Pylon (Not included in your material list! If you want to buy one visit here.)

Tools:

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

1 x 2 mm L Shape Allen
1 x 1.5 mm Allen
1 x 2 mm Allen
1 x 3 mm Allen
1 x 2.5 mm T Handle Allen

Assembly Video:


Step 7 – Finally let’s add the motor

Materials:

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

1 x Step 6 Subassembly
1 x a1007_encoderKnee
3 x Super-Corrosion-Resistant 316 Stainless Steel Socket Head Screw (vendor: McMaster, part no: 92290A745)
1 x a0002_actuator
4 x p1022_standoffSlotted
4 x 18-8 Stainless Steel Low-Profile Socket Head Screws (vendor: McMaster, part no: 92855A309)
4 x 18-8 Stainless Steel Low-Profile Socket Head Screws (vendor: McMaster, part no: 92855A310)

Tools:

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

1 x 1.5 mm L Shape Allen
1 x 2 mm L Shape Allen
1 x 2 mm Allen

Assembly Video: