How-To Build: Weight bearing alert device

• 1. Christopher Weber Jennifer Diercks

2. Clients with non-weight bearing precautions in lower extremity Orthopedic Surgeries Total Hip Replacement Total Knee Replacement 3. Weight bearing restrictions are needed to provide adequate time for proper bone healing. It helps the hardware that was placed during the surgical procedure to stay in the correct place. Understanding verbal instructions of these precautions is hard for patients to understand. 4. MaterialCostCan Purchase at:Shoe Insoles (pack of 4)$1.99Wal-Mart22 gage wire$1.06AmazonDoorbell Kit$15.97Wal-Mart1/8 mono plug$.97Radio Shack1/8 mono jack$.97Radio Shack1/8 heat shrink tubing$3.30Radio ShackPlasti Dip Spray$5.98LowesMuslin Fabric$1.99/ftJoAnns Fabric36 gage copper roll (1/5 used)$13.99/ 12x30JoAnns FabricSticky Back Velcro (1/2 used)$7.49JoAnns FabricPacking Foam$.50/ftPack N MailElectrical Tape$.99MenardsHair Clip$.50JoAnns FabricApproximate Cost for 1 Device: $41.19 5. Scissors Wire Cutter Dremel Tool Screwdriver Hot Glue Gun Soldering Gun Solder Tin Snip Sewing Machine Needle & Thread Permanent Marker Nail X-Acto Knife Hanger Sewing Pins 6. Cut a 12 x 6 sheet of 36 gage copper from roll. Lay 2 shoe insoles on top of the piece of copper. 7. Make an outline of the insoles with a permanent marker onto the copper 8. Cut the copper along both outlines with a pair of tin snips. 9. Poke a small hole in the toe of each piece of copper using a nail. 10. Strip both ends of 2 strands of the 22 gauge wire using wire strippers 11. Place the end of the wire through the hole in each copper plate and solder in place 12. Place each copper plate on top the insoles 13. Using electrical tape, fasten the copper sheets to the insoles. 14. Make sure the electrical tape covers all edges of the metal slightlyPlace one side of the sensor on top of packaging foam and outline using permanent marker 15. Using scissors or XActo knife, cut around the marked boarder 16. Cut holes in the packaging foam leaving about a boarder around each hole. 17. Place fully cut packaging foam inbetween the copper side of each insole 18. Using electrical tape, cover the packaging foam by taping together the two insoles 19. Cover the wire with 1/8 heat shrink tubing. 20. Solder wires into separate holes in 1/8 mono plug 21. Do not cover insole sensor with fabric prior to testing electrical connection and the amount of force required to trigger alarm Foot sensor as shown requires approximately 10 pounds to activate If you want more weight to trigger the alarm make the holes in the packing foam smaller If you want less weight to trigger the alarm make the holes in the packing foam larger 22. Doorbell chimeWireless doorbell switch 23. Place small flat tip screwdriver in slot labeled open, gently lift top cover 24. Remove the protective plate by unscrewing the two retention screws using a small screwdriver. Set protective plate aside and remove circuit board 25. Strip both ends of 2 strands of 22 gage wire using a wire stripper 26. On the back of the circuit board locate the two connections to the button that activates the doorbell chime Solder 1 of the 22 gauge wires to each of these connections 27. The circuit board and soldered connections should look similar to this 28. Drill a hole through the back of the wireless door switch using a Dremel Hole placement and size will depend on the how big the wires are exiting the back 29. Feed soldered wires through the hole in the back of the wireless doorbell switch Reassemble switch by replacing protective cover and top cover 30. Apply hot glue using a glue gun around the back hole in the wireless door switch to secure the wires in place 31. Cover the wires with 1/8 heat shrink tubing 32. Solder wires into separate holes in 1/8 mono jack 33. Gently heat the 1/8 heat shrink tubing using a heat gun. 34. Hot glue gun a metal hair clip onto the back of the door bell switch. The clip is used to secure the doorbell switch to the clients shoe 35. Perform a test of the device at this time by plugging mono plug into mono jack Make adjustments as noted in the foot sensor suggestions section 36. 1. Trace around foot sensor using a marker2. Cut the muslin fabric about an 1 bigger then the marked outline 37. 1. Pin together two cutout patterns 2. Sew approximately 1/8 away from traced line 3. Leave enough unsewn gap to slide sensor in the case. Also, leave small unsewn hole in toe area for wires to exit. Size *Will vary depending on type and size of insoles purchased. 38. 1. Slide muslin sleeve over sensor. Feed wire through the hole left in the toe of the sleeve2. Hand sew the rest of the cover so that the sensory is fully enclosed. 39. 1. Spray muslin fabric with Plasti Dip Spray. Apply at least 4 coats. Between coats let dry 30-45 minutes. Follow application instructions on spray bottle.2. Once dry place a piece of sticky back hook Velcro on both sidesof the sensor. 40. To keep floor side Velcro from sticking to floor when not in use add a piece of loop Velcro over the hook Velcro 41. Apply sticky back loop Velcro to the bottom of clients shoe Attach sensor to the bottom of shoe Insert foot sensor plug into doorbell jack Clip doorbell switch to the clients shoe laces