surgical instrument with hardware-only control circuit

专利摘要:
The present invention relates to a surgical instrument. The surgical instrument includes an electric motor and a control circuit. The control circuit includes a plurality of logic gates and a monostable multivibrator. The monostable multivibrator is connected to a first of the logic gates. The control circuit is configured to change an action rate of a surgical instrument function by controlling the rotational speed of the electric motor based on a detected parameter.
公开号:BR112020012958A2
申请号:R112020012958-5
申请日:2018-12-19
公开日:2020-12-01
发明作者:Frederick E. Shelton Iv；David C. Yates；Gregory J. Bakos；Jason L. Harris
申请人:Ethicon Llc；
IPC主号:

专利说明:

[0001] [0001] The present application claims the benefit of US non-provisional patent application Serial No. 16/220,281, entitled SURGICAL INSTRUMENT WITH A HARDWARE-ONLY CONTROL CIRCUIT, filed on December 14, 2018, the disclosure of which is incorporated herein for reference in its entirety. The present application claims the benefit of US Provisional Patent Application Serial No. 62/778,571, entitled SURGICAL INSTRUMENT SYSTEMS, filed December 12, 2018, the disclosure of which is incorporated herein by reference in its entirety. The present application claims the benefit of US provisional patent application serial no. 62/750,539, titled SURGICAL CLIP APPLIER, filed October 25, 2018, and US Provisional Patent Application Serial No. 62/750,555, titled SURGICAL CLIP APPLIER, filed October 25, 2018, the disclosures of which are here incorporated by way of reference in their entirety. The present application claims the benefit of US Provisional Patent Application Serial No. 62/659,900, titled METHOD OF HUB COMMUNICATION, filed April 19, 2018, the disclosure of which is incorporated herein by reference, in its entirety. ty. The present application claims the benefit of US Provisional Patent Application Serial No. 62/665,128 entitled MODULAR SURGICAL INSTRUMENTS, filed May 1, 2018, US Provisional Patent Application Serial No. 62/665,129 , entitled SURGICAL SUTURING
[0002] [0002] The present disclosure pertains to surgical systems and, in various arrangements, grasping instruments that are designed to grip a patient's tissue, dissection instruments configured to manipulate a patient's tissue, clinic applicators, feet configured to pinch tissue from a patient, and suturing instruments configured to suture tissue from a patient, among others. BRIEF DESCRIPTION OF THE DRAWINGS
[0003] [0003] Several characteristics of the modalities described here, along with their advantages, can be understood according to the description presented below, considered together with the attached drawings, as shown below:
[0004] [0004] Figure 1 illustrates a surgical system comprising a handle and several drive shaft assemblies, each of which are selectively attachable to the handle, according to at least one embodiment;
[0005] [0005] Figure 2 is an elevation view of the handle and one of the drive shaft assemblies of the surgical system of Figure 1;
[0006] [0006] Figure 3 is a perspective view in partial cross-section of the drive shaft assembly of Figure 2;
[0007] [0007] Figure 4 is another perspective view in partial cross-section of the drive shaft assembly of Figure 2;
[0008] [0008] Figure 5 is a partial exploded view of the drive shaft assembly of Figure 2;
[0009] [0009] Figure 6 is an elevation view in partial cross-section of the drive shaft assembly of Figure 2;
[0010] [0010] Figure 7 is an elevation view of a handle actuation module of Figure 1;
[0011] [0011] Figure 8 is a perspective view in cross section of the drive module of Figure 7;
[0012] [0012] Figure 9 is an end view of the drive module of Figure 7;
[0013] [0013] Figure 10 is a partial cross-sectional view of the interconnection between the handle and the drive shaft assembly of Figure 2 in a locked configuration;
[0014] [0014] Figure 11 is a partial cross-sectional view of the interconnection between the handle and the drive shaft assembly of Figure 2 in an unlocked configuration;
[0015] [0015] Figure 12 is a perspective view in cross section of a motor and a speed reduction gear assembly of the drive module of Figure 7;
[0016] [0016] Figure 13 is an end view of the speed reduction gear assembly of Figure 12;
[0017] [0017] Figure 14 is a partial perspective view of an end actuator of the Figure 2 drive shaft assembly in an open configuration;
[0018] [0018] Figure 15 is a partial perspective view of the end actuator of Figure 14 in a closed configuration;
[0019] [0019] Figure 16 is a partial perspective view of the end actuator of Figure 14 articulated in a first direction;
[0020] [0020] Figure 17 is a partial perspective view of the end actuator of Figure 14 articulated in a second direction;
[0021] [0021] Figure 18 is a partial perspective view of the end actuator of Figure 14 rotated in a first direction;
[0022] [0022] Figure 19 is a partial perspective view of the end actuator of Figure 14 rotated in a second direction;
[0023] [0023] Figure 20 is a perspective view in partial cross-section of the end actuator of Figure 14 separated from the drive shaft assembly of Figure 2;
[0024] [0024] Figure 21 is an exploded view of the end actuator of Figure 14 illustrated with some components removed;
[0025] [0025] Figure 22 is an exploded view of a distal attachment portion of the drive shaft assembly of Figure 2;
[0026] [0026] Figure 22A is an exploded view of the distal portion of the drive shaft assembly of Figure 2 illustrated with some components removed;
[0027] [0027] Figure 23 is another perspective view in partial cross-section of the end actuator of Figure 14 separated from the drive shaft assembly of Figure 2;
[0028] [0028] Figure 24 is a perspective view in partial cross-section of the end actuator of Figure 14 attached to the drive shaft assembly of Figure 2;
[0029] [0029] Figure 25 is a perspective view in partial cross-section of the end actuator of Figure 14 attached to the drive shaft assembly of Figure 2;
[0030] [0030] Figure 26 is another perspective view in partial cross-section of the end actuator of Figure 14 attached to the drive shaft assembly of Figure 2;
[0031] [0031] Figure 27 is a partial cross-sectional view of the end actuator of Figure 14 attached to the drive shaft assembly of Figure 2 showing first, second and third end actuator clutches;
[0032] [0032] Figure 28 shows the first clutch of Figure 27 in a non-actuated condition;
[0033] [0033] Figure 29 shows the first clutch of Figure 27 in an actuated condition;
[0034] [0034] Figure 30 shows the second clutch of Figure 27 in a non-actuated condition;
[0035] [0035] Figure 31 shows the second clutch of Figure 27 in an actuated condition;
[0036] [0036] Figure 32 shows the third clutch of Figure 27 in a non-actuated condition;
[0037] [0037] Figure 33 shows the third clutch of Figure 27 in an actuated condition;
[0038] [0038] Figure 34 shows the second and third clutches of Figure 27 in their non-actuated conditions and the end actuator of Figure 14 locked to the drive shaft assembly of Figure 2;
[0039] [0039] Figure 35 shows the second clutch of Figure 27 in its non-actuated condition and the third clutch of Figure 27 in its actuated condition;
[0040] [0040] Figure 36 shows the second and third clutches of Figure 27 in their actuated conditions and the end actuator of Figure 14 unlocked from the drive shaft assembly of Figure 2;
[0041] [0041] Figure 37 is a partial cross-sectional view of a drive shaft assembly according to at least one alternative modality that comprises sensors configured to detect the conditions of the first, second and third clutches of the Fi- figure 27;
[0042] [0042] Figure 38 is a partial cross-sectional view of a drive shaft assembly according to at least one alternative modality that comprises sensors configured to detect the conditions of the first, second and third clutches of the Fi- figure 27;
[0043] [0043] Figure 39 shows the first and second clutches of Figure 38 in their non-actuated conditions and a sensor according to at least one alternative modality;
[0044] [0044] Figure 40 shows the second and third clutches of Figure 38 in their non-actuated conditions and a sensor according to at least one alternative modality;
[0045] [0045] Figure 41 is a partial cross-sectional view of a drive shaft assembly according to at least one modality;
[0046] [0046] Figure 42 is a partial cross-sectional view of the drive shaft assembly of Figure 41 comprising a clutch illustrated in a non-actuated condition;
[0047] [0047] Figure 43 is a partial cross-sectional view of the drive shaft assembly of Figure 41 illustrating the clutch in an actuated configuration;
[0048] [0048] Figure 44 is a partial cross-sectional view of a drive shaft assembly, according to at least one mode, comprising the first and second clutches illustrated in a non-actuated condition;
[0049] [0049] Figure 45 is a perspective view of the handle actuation module of Figure 7 and one of the actuation shaft assemblies of the surgical system of Figure 1;
[0050] [0050] Figure 46 is another perspective view of the handle actuation module of Figure 7 and the drive shaft assembly of Figure 45;
[0051] [0051] Figure 47 is a partial cross-sectional view of the drive shaft assembly of Figure 45 attached to the handle of Figure 1;
[0052] [0052] Figure 48 is another partial cross-sectional view of the drive shaft assembly of Figure 45 attached to the handle of Figure 1;
[0053] [0053] Figure 49 is a perspective view in partial cross-section of the drive shaft assembly of Figure 45;
[0054] [0054] Figure 50 is a schematic of the control system of the surgical system of Figure 1;
[0055] [0055] Figure 51 is an elevation view of the handle and one of the drive shaft assemblies of the surgical system of Figure 1;
[0056] [0056] Figure 52 is a perspective view of the handle of Figure 1 and the drive shaft assembly of Figure 2;
[0057] [0057] Figure 53 is a top plan view of the handle of Figure 1 and the drive shaft assembly of Figure 2;
[0058] [0058] Figure 54 is a partial elevation view of the handle of Figure 1 and the drive shaft assembly of Figure 2;
[0059] [0059] Figure 55 is a perspective view of the drive module of Figure 7 and a power module of Figure 1;
[0060] [0060] Figure 56 is a perspective view of the drive module of Figure 7 and the power module of Figure 55;
[0061] [0061] Figure 57 is an elevation view of the drive module of Figure 7 and the power module of Figure 55 attached to a side battery door of the drive module;
[0062] [0062] Figure 58 is a partial cross-sectional view of the connection between the battery side door of the drive module of Figure 7 and the power module of Figure 55;
[0063] [0063] Figure 59 is an elevation view of the handle actuation module of Figure 7, the power module of Figure 45 attached to a proximal battery port of the handle actuation module, and the drive shaft assembly of Figure 45 attached to the drive module;
[0064] [0064] Figure 60 is a top view of the drive module of Figure 7 and the power module of Figure 45 attached to the proximal battery port;
[0065] [0065] Figure 61 is an elevation view of the drive module of Figure 7 and the power module of Figure 45 attached to the proximal battery port;
[0066] [0066] Figure 62 is a perspective view of the drive module of Figure 7 and the power module of Figure 45 attached to the proximal battery port;
[0067] [0067] Figure 63 is a perspective view of the power module of Figure 45 disconnected from the drive module of Figure 7;
[0068] [0068] Figure 64 is another perspective view of the power module of Figure 45 disconnected from the drive module of Figure 7;
[0069] [0069] Figure 65 is an elevation view of the power module of Figure 45 attached to the proximal battery port of the drive module of Figure 7;
[0070] [0070] Figure 66 is a partial cross-sectional view of the connection between the proximal battery port of the drive module of Figure 7 and the power module of Figure 45;
[0071] [0071] Figure 67 is an elevation view of the power module of Figure 55 attached to the proximal battery port of the drive module of Figure 7;
[0072] [0072] Figure 68 is a partial cross-sectional view of the connection between the proximal battery port of the drive module of Figure 7 and the power module of Figure 55;
[0073] [0073] Figure 69 is an elevation view of an attempt to connect the power module of Figure 45 to the side battery port of the drive module of Figure 7;
[0074] [0074] Figure 70 is a cross-sectional detail view of an attempt to connect the power module of Figure 45 to the battery side port of the drive module of Figure 7;
[0075] [0075] Figure 71 is a perspective view of the power module of Figure 45 attached to the proximal battery port of the drive module of Figure 7 and the power module of Figure 55 attached to the side battery port;
[0076] [0076] Figure 72 is a cross-sectional view of the power module of Figure 45 attached to the proximal battery port of the drive module of Figure and of the power module of Figure 55 attached to the side battery port;
[0077] [0077] Figure 73 is a perspective view of a portion of a surgical instrument comprising selectively attachable modular components in accordance with at least one aspect of the present disclosure;
[0078] [0078] Figure 74 illustrates an electrical architecture of the surgical instrument of Figure 73 according to at least one aspect of the present disclosure;
[0079] [0079] Figure 75 is a perspective view in partial cross-section of a handle of the surgical instrument of Figure 73 in accordance with at least one aspect of the present disclosure;
[0080] [0080] Figure 76 is a perspective view of a system of magnetic elements disposed on the handle and a drive shaft of the surgical instrument of Figure 73, in accordance with at least one aspect of the present disclosure;
[0081] [0081] Figure 77 is a perspective view of a system of magnetic elements arranged in the handle and drive shaft of the surgical instrument of Figure 73, according to at least one aspect of the present disclosure;
[0082] [0082] Figure 78 is a perspective view of the magnetic element system of Figure 77 aligning the drive shaft with the handle of the surgical instrument, in accordance with at least one aspect of the present disclosure;
[0083] [0083] Figure 79 is a perspective view of a flexible circuit for use in the surgical instrument of Figure 73, in accordance with at least one aspect of the present disclosure;
[0084] [0084] Figure 79A is a perspective view in detail of a primary stress relieving portion of the flexible circuit of Figure 79, in accordance with at least one aspect of the present disclosure;
[0085] [0085] Figure 79B is a perspective view in detail of a secondary stress relieving portion of the flexible circuit of Figure 79, in accordance with at least one aspect of the present disclosure;
[0086] [0086] Figure 79C is a perspective view in detail of control circuit components incorporated into a flexible plastic of the flexible circuit of Figure 79, in accordance with at least one aspect of the present disclosure;
[0087] [0087] Figure 80 is a perspective view of a flexible circuit for use in combination with the flexible circuit of Figure 79, in accordance with at least one aspect of the present disclosure;
[0088] [0088] Figure 81A is a perspective view of the flexible circuit of Figure 79 before being electrically coupled to the flexible circuit of Figure 80, in accordance with at least one aspect of the present disclosure;
[0089] [0089] Figure 81B is a perspective view of the flexible circuit of Figure 79 electrically coupled to the flexible circuit of Figure 80, in accordance with at least one aspect of the present disclosure;
[0090] [0090] Figure 82 is an elevation view of a surgical instrument according to at least one modality;
[0091] [0091] Figure 82A is a partial detail view of the surgical instrument of Figure 82;
[0092] [0092] Figure 82B is a partial detail view of the surgical instrument of Figure 82 illustrating a probe inserted into a handle of the surgical instrument;
[0093] [0093] Figure 82C is a perspective view of a trocar, according to at least one modality, configured to facilitate the insertion of the surgical instrument of Figure 82, for example, in a patient;
[0094] [0094] Figure 83 is a perspective view of a drive system of the surgical instrument of Figure 82;
[0095] [0095] Figure 84 is a perspective view of a drive system according to at least one embodiment;
[0096] [0096] Figure 85 is a perspective view of a strain gauge of the surgical instrument of Figure 82;
[0097] [0097] Figure 85A shows the strain gauge of Figure 85 in an elongated condition;
[0098] [0098] Figure 85B shows the strain gauge of Figure 85 in a contracted condition;
[0099] [0099] Figure 85C illustrates a Wheatstone bridge that comprises a strain gauge according to at least one modality;
[0100] [0100] Figure 86 is a perspective view of half a housing of the surgical instrument handle of Figure 82;
[0101] [0101] Figure 87 is a partial perspective view of circuit boards in the grip of Figure 86;
[0102] [0102] Figure 88 is a partial cross-sectional view of a surgical instrument according to at least one embodiment;
[0103] [0103] Figure 89 is a partial detail view of an electrical interface within the surgical instrument of Figure 88;
[0104] [0104] Figure 90 is a perspective view of a handle according to at least one embodiment;
[0105] [0105] Figure 91 is a perspective view of a button housing of the grip of Figure 90;
[0106] [0106] Figure 92 is a perspective view of another button housing of the grip of Figure 90;
[0107] [0107] Figure 93 is a perspective view of another button housing of the grip of Figure 90;
[0108] [0108] Figure 94 is a cross-sectional view of a button wrap according to at least one embodiment;
[0109] [0109] Figure 95 is a cross-sectional view of a button wrap according to at least one embodiment;
[0110] [0110] Figure 96 is a perspective view of a surgical instrument handle according to at least one embodiment;
[0111] [0111] Figure 97 is a perspective view of a surgical instrument handle according to at least one embodiment;
[0112] [0112] Figure 98 is a perspective view of a surgical instrument handle according to at least one embodiment;
[0113] [0113] Figure 99 is an icon that can be shown on a surgical instrument according to at least one modality;
[0114] [0114] Figure 100 is an icon that can be shown on a surgical instrument according to at least one modality;
[0115] [0115] Figure 101 is an icon that can be shown on a surgical instrument according to at least one modality;
[0116] [0116] Figure 101A illustrates a flexible circuit of the handle and a flexible circuit of the drive shaft of a surgical instrument according to at least one embodiment;
[0117] [0117] Figure 101B illustrates a connection between the flexible circuit of the handle and the flexible circuit of the drive shaft of Figure 101A;
[0118] [0118] Figure 102 illustrates a control circuit of a surgical instrument according to at least one modality;
[0119] [0119] Figure 103 illustrates timing diagrams associated with the control circuit of Figure 102, according to at least one modality;
[0120] [0120] Figure 104 illustrates a control circuit of a surgical instrument, according to at least one modality;
[0121] [0121] Figure 104A illustrates a control circuit configured to indicate the energy supplied to an electric motor according to at least one modality;
[0122] [0122] Figure 104B illustrates a graduated display in communication with the control circuit of Figure 104A, according to at least one modality;
[0123] [0123] Figure 104C illustrates a surgical instrument comprising a handle according to at least one modality;
[0124] [0124] Figure 105 illustrates a surgical system according to at least one modality;
[0125] [0125] Figure 106 illustrates a schematic diagram representing current and signal paths of the surgical system of Figure 105 according to at least one modality;
[0126] [0126] Figure 107 illustrates a graph showing a relationship between a patient's level of continuity and a level of electro-surgical energy provided by the surgical system of Figure 105 according to at least one modality;
[0127] [0127] Figure 108 illustrates a flexible circuit of a surgical instrument according to at least one modality;
[0128] [0128] Figure 109 illustrates a cross section of the flexible circuit of Figure 108;
[0129] [0129] Figure 110 illustrates a flexible circuit of a surgical instrument, according to at least one modality;
[0130] [0130] Figure 111 illustrates a cross section of the flexible circuit of Figure 110;
[0131] [0131] Figure 111A illustrates a flexible circuit of a surgical instrument according to at least one embodiment;
[0132] [0132] Figure 112 illustrates a control circuit of a surgical instrument, according to at least one modality;
[0133] [0133] Figure 113 illustrates a method to identify the degradation or failure of components of a surgical instrument according to at least one modality;
[0134] [0134] Figure 114 illustrates a graph showing frequency component signals of acoustic signatures of components of a surgical instrument according to at least one modality;
[0135] [0135] Figure 115 illustrates components associated with the frequency component signals of Figure 114;
[0136] [0136] Figure 116 illustrates a method to identify the degradation or failure of drive components of a surgical instrument according to at least one modality;
[0137] [0137] Figure 117 illustrates a graph showing a relationship between the current drawn from the motor and the frequency component signals of a surgical instrument according to at least one modality;
[0138] [0138] Figure 118 illustrates a method for adjusting a surgical instrument motor control algorithm according to at least one modality;
[0139] [0139] Figure 119 illustrates an environment of a surgical procedure according to at least one modality;
[0140] [0140] Figure 120 illustrates a monopolar surgical instrument according to at least one modality;
[0141] [0141] Figures 121 and 122 illustrate electrical terminations of the monopolar surgical instrument of Figure 120;
[0142] [0142] Figure 123 illustrates a graph showing a relationship between leakage current and distances between surgical instruments in accordance with at least one aspect of the present disclosure;
[0143] [0143] Figure 124 illustrates a graph showing direct current (DC) output voltage limits for different types of surgical instrument contact according to at least one modality;
[0144] [0144] Figure 125 illustrates a surgical instrument equipped with a motor according to at least one embodiment;
[0145] [0145] Figure 126 illustrates a graph showing the electrical potential associated with the motor-equipped surgical instrument of Figure 125 according to at least one modality;
[0146] [0146] Figure 127 illustrates a scheme of active transmission and detection used by a surgical instrument according to at least one modality;
[0147] [0147] Figure 128 illustrates a graph showing signals transmitted and received by the surgical instrument of Figure 127;
[0148] [0148] Figure 129 illustrates a graph showing proximity measurements associated with the surgical instrument of Figure 127;
[0149] [0149] Figure 130 illustrates a passive detection scheme used by a surgical instrument according to at least one modality;
[0150] [0150] Figure 131 illustrates a primary magnetic field associated with the surgical instrument of Figure 130 in an unaffected condition;
[0151] [0151] Figure 132 illustrates a primary magnetic field associated with the surgical instrument of Figure 130 in an affected condition;
[0152] [0152] Figure 133 illustrates a graph showing the Hall current associated with the surgical instrument of Figure 130 according to at least one modality;
[0153] [0153] Figures 134 and 135 illustrate a passive detection scheme used by a surgical instrument according to at least one modality;
[0154] [0154] Figure 136 illustrates a schematic view of a surgical instrument according to at least one modality;
[0155] [0155] Figure 137 illustrates a graph showing the induced current measured by a current sensor of the surgical instrument of Figure 136 according to at least one modality;
[0156] [0156] Figure 138 illustrates a surgical instrument according to at least one modality; illustrated with components removed;
[0157] [0157] Figure 139 illustrates an electrical circuit of the surgical instrument of Figure 138;
[0158] [0158] Figure 140 illustrates a graph showing the relationships between altitude, atmospheric pressure and the electrical energy used by a surgical instrument according to at least one modality;
[0159] [0159] Figure 141 illustrates a method to predict when a predefined temperature threshold will be exceeded according to at least one modality; and
[0160] [0160] Figure 142 illustrates a graph showing a relationship between a detected temperature, an approximate temperature, and a power consumption of a surgical instrument according to at least one modality.
[0161] [0161] Corresponding reference characters indicate corresponding parts across the various views. The examples described herein illustrate various embodiments of the invention, in one form, and such examples are not to be considered in any way limiting the scope of the invention. DETAILED DESCRIPTION
[0162] [0162] The applicant of the present application holds the following US patent applications that were filed on December 14, 2018, which are each incorporated herein by reference in their entirety: - US patent application no. serial 16/220,301, entitled SURGICAL INSTRUMENT WITH ACOUSTIC-BASED MOTOR CONTROL; - US patent application serial no. 16/220,313, entitled SURGICAL INSTRUMENT COMPRISING A PLURALITY OF DRIVE SYSTEMS; - US patent application serial no. 16/220,296, entitled SURGICAL INSTRUMENT COMPRISING A CONTROL CIRCUIT;
[0163] [0163] The applicant of the present application holds the following US provisional patent applications, filed on December 12, 2018, each of which is incorporated herein by reference in its entirety: - US provisional patent application serial no. 62/778,571, entitled SURGICAL INSTRUMENT SYSTEMS; - provisional US patent application serial no. 62/778,572, entitled SURGICAL INSTRUMENT SYSTEMS; and - US provisional patent application serial no. 62/778,573, entitled SURGICAL INSTRUMENT SYSTEMS.
[0164] [0164] The applicant of the present application holds the following US patent applications that were filed on October 26, 2018 and which are each incorporated herein by reference in their entirety: - US patent application no. No. 16/172,130, entitled CLIP APPLIER COMPRISING INTERCHANGEABLE CLIP RELOADS; - US patent application serial no. 16/172,066, entitled CLIP APPLIER COMPRISING A MOVABLE CLIP MAGAZINE; - US patent application serial no. 16/172,078, entitled CLIP APPLIER COMPRISING A ROTATABLE CLIP MAGAZINE; - US patent application serial no. 16/172,087, entitled
[0165] [0165] The applicant of the present application holds the following US patent applications that were filed on October 26, 2018 and which are each incorporated herein by reference in their entirety: - US patent application no. Serial No. 16/172,328, entitled METHOD OF HUB COMMUNICATION WITH SURGICAL INSTRUMENT SYSTEMS; - US patent application serial no. 16/172,280, entitled METHOD FOR PRODUCING A SURGICAL INSTRUMENT COMPRISING A SMART ELECTRICAL SYSTEM; - US patent application serial no. 16/172,219, entitled METHOD OF HUB COMMUNICATION WITH SURGICAL INSTRUMENT SYSTEMS; - US patent application serial no. 16/172,248, entitled METHOD FOR COMMUNICATING WITH SURGICAL INSTRUMENT SYSTEMS;
[0166] [0166] The applicant of the present application holds the following US patent applications that were filed on August 24, 2018 and which are each incorporated herein by reference in their entirety: - US patent application no. Serial No. 16/112,129, entitled SURGICAL SUTURING INSTRUMENT CONFIGURED TO MANIPULATE TISSUE USING MECHANICAL AND ELECTRICAL POWER; - US patent application serial no. 16/112,155, entitled SUR-
[0167] [0167] The applicant of this application holds the following US patent applications that were filed on May 1, 2018, and which are each incorporated herein by reference in their entirety: - Provisional patent application US Serial No. 62/665,129 entitled SURGICAL SUTURING SYSTEMS; - US patent application serial no. 62/665,139, entitled SURGICAL INSTRUMENTS COMPRISING CONTROL SYSTEMS; - US patent application serial no. 62/665,177, entitled SURGICAL INSTRUMENTS COMPRISING HANDLE ARRANGEMENTS;
[0168] [0168] The applicant of the present application holds the following US patent applications that were filed on February 28, 2018, and which are each incorporated herein by reference in their entirety: - US patent application Serial No. 15/908,021, entitled SURGICAL INSTRUMENT WITH REMOTE RELEASE; - US patent application serial no. 15/908,012, entitled
[0169] [0169] The applicant of the present application holds the following US patent applications that were filed on October 30, 2017, and which are each incorporated herein by reference in their respective entireties:
[0170] [0170] The applicant of the present application holds the following provisional US patent applications, filed on December 28, 2017, the disclosure of each of which is incorporated herein by reference in their entirety: - Application for US Provisional Patent Serial No. 62/611,341 entitled INTERACTIVE SURGICAL PLATFORM; - provisional US patent application serial no. 62/611,340, entitled CLOUD-BASED MEDICAL ANALYTICS; and - US provisional patent application serial no. 62/611,339, entitled ROBOT ASSISTED SURGICAL PLATFORM.
[0171] [0171] The applicant of the present application holds the following US provisional patent applications, filed on March 28, 2018,
[0172] [0172] The applicant of the present application holds the following US patent applications, filed on March 29, 2018, each of which is incorporated herein by reference in its entirety: - US patent application serial no. 15/940,641, entitled INTERACTIVE SURGICAL SYSTEMS WITH encrypted COMMUNICATION CAPABILITIES; - US patent application serial no. 15/940,648, entitled IN-
[0173] [0173] The applicant of the present application holds the following US patent applications, filed on March 29, 2018, each of which is incorporated herein by reference in its entirety: - US patent application serial no. 15/940,636, entitled ADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICAL DEVICES; - US patent application serial no. 15/940,653, entitled ADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICAL HUBS; - US patent application serial no. 15/940,660, entitled CLOUD-BASED MEDICAL ANALYTICS FOR CUSTOMIZATION AND RECOMMENDATIONS TO A USER; - US patent application serial no. 15/940,679, entitled CLOUD-BASED MEDICAL ANALYTICS FOR LINKING OF LOCAL US-
[0174] [0174] The applicant of the present application holds the following US patent applications, filed on March 29, 2018, each of which is incorporated herein by reference in its entirety: - US patent application serial no. 15/940,627 entitled DRIVE ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLAT-FORMS; - US patent application serial no. 15/940,637, entitled COMMUNICATION ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; - US patent application serial no. 15/940,642, entitled CONTROLS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; - US patent application serial no. 15/940,676, entitled AUTOMATIC TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; - US patent application serial no. 15/940,680, entitled CONTROLLERS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; - US patent application serial no. 15/940,683, entitled CO-OPERATIVE SURGICAL ACTIONS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; - US patent application serial no. 15/940,690, entitled DISPLAY ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; and
[0175] [0175] The applicant of the present application holds the following US provisional patent applications, filed on March 30, 2018, each one being incorporated herein by reference in their entirety: - US provisional patent application no. serial 62/650,887, entitled SURGICAL SYSTEMS WITH OPTIMIZED SENSING CAPABILITIES; - provisional US patent application serial no. 62/650,877, entitled SURGICAL SMOKE EVACUATION SENSING AND CONTROLS; - US provisional patent application serial no. 62/650,882, entitled SMOKE EVACUATION MODULE FOR INTERACTIVE SURGICAL PLATFORM; and - US provisional patent application serial no. 62/650,898, entitled CAPACITIVE COUPLED RETURN PATH PAD WITH SEPARABLE ARRAY ELEMENTS.
[0176] [0176] The applicant of the present application holds the following US provisional patent application, filed on April 19, 2018, which is incorporated herein by reference in its entirety: - US Provisional Patent Application Serial No. 62/659,900 , entitled METHOD OF HUB COMMUNICATION.
[0177] [0177] The applicant of this application holds the following US provisional patent applications, filed on Thursday, October 25, 2018, each of which is incorporated herein by reference in its entirety: - patent application provisional US Serial No. 62/750,529 entitled METHOD FOR OPERATING A POWERED ARTICULATING MULTI-CLIP APPLIER;
[0178] [0178] Numerous specific details are presented to provide a complete understanding of the structure, function, manufacture and general use of the modalities described in the specification and illustrated in the attached drawings. Well-known operations, components and elements were not described in detail, so as not to obscure the modalities described in the descriptive report. The reader will understand that the embodiments described and illustrated in the present invention are non-limiting examples, and therefore, it can be understood that the specific structural and functional details disclosed in the present invention may be representative and illustrative. Variations and changes may be made to this without deviating from the scope of the claims.
[0179] [0179] The terms "comprise" (and any form of understanding, such as "comprises" and "which comprises"), "have" (and any form of having, such as "has" and "has"), " include" (and any form of include, such as "includes" and "which includes") and "contain" (and any form of contain, such as "contains" and "which contains") are non-limited linking verbs. As a result, a surgical system, device or device that "comprises", "has", "includes" or "contains" one or more elements has those one or more elements, but is not limited to having only those one or more elements. elements. Likewise, an element of a system, device or surgical device that "comprises", "has", "includes" or "contains" one or more features has those one or more features, but is not limited to having only those one or more features. or more resources.
[0180] [0180] The terms "proximal" and "distal" are used in the present in-
[0181] [0181] Various devices and exemplifying methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily understand that the various methods and devices disclosed in the present invention can be used in numerous surgical procedures and applications, including, for example, open surgical procedures. As the present Detailed Description advances, the reader will further understand that the various instruments disclosed herein may be inserted into a body in any manner, such as through a natural orifice, through an incision or perforation formed in tissue, etc. . The functional portions or end actuator portions of instruments may be inserted directly into a patient's body or may be inserted through an access device that has a working channel through which the end actuator and elongated drive shaft of a surgical instrument can be advanced.
[0182] [0182] A surgical instrument, such as a gripper, may comprise a handle, a drive shaft that extends from the handle, and an end actuator that extends from the drive shaft. In many cases, the end actuator comprises a first jaw and a second jaw, one or both jaws being movable relative to each other to grip a patient's tissue. That said, an end actuator of a surgical instrument may comprise any suitable arrangement and may perform any suitable function. For example, an end actuator may comprise first and second jaws configured to dissect or separate tissue from a patient. Also, for example, an end actuator can be configured to suture and/or clamp tissue from a patient. In many cases, the end actuator and/or drive shaft of the surgical instrument are configured to be inserted into a patient through a trocar, or cannula, and can be of any suitable diameter, such as approximately 5 mm, 8 mm and/or 12 mm, for example. US Patent Application Serial No. 11/013,924, entitled TROCAR SEAL ASSEMBLY, now US Patent No. 7,371,227, is hereby incorporated by reference in its entirety. The drive shaft may define a longitudinal axis and at least a portion of the end actuator may be rotatable about the longitudinal axis. Furthermore, the surgical instrument may additionally comprise an articulation joint which may enable at least a portion of the end actuator to be articulated with respect to the drive shaft. In use, a clinician can rotate and/or pivot the extremity actuator to maneuver the extremity actuator on the patient.
[0183] [0183] A surgical instrument system is shown in Figure
[0184] [0184] Again with reference to Figure 1, the grip assembly 1000 comprises, among other things, a drive module
[0185] [0185] In addition to the above, again with reference to Figures 1 and 2, the handle drive module 1100 comprises a cabinet 1110, a first module connector 1120, and a second module connector 1120'. Power module 1200 comprises an enclosure 1210, a connector 1220, one or more unlocking latches 1250, and one or more batteries 1230. Connector 1220 is configured to mate with the first module connector 1120 of the drive module 1100. to secure the power module 1200 to the drive module 1100. Connector 1220 comprises one or more latches 1240 that mechanically couple and securely secure the cabinet 1210 of the power module 1200 to the cabinet 1110 of the drive module 1100. Latches 1240 are movable to disengaged positions when unlocking latches 1250 are pressed so that power module 1200 can be separated from drive module 1100. Connector 1220 also comprises one or more electrical contacts that place batteries 1230, and/or an electrical circuit including batteries 1230, in electrical communication with an electrical circuit in the drive module 1100.
[0186] [0186] In addition to the above, again with reference to Figures 1 and 2, the power module 1300 comprises a cabinet 1310,
[0187] [0187] In addition to the above, the power module 1200, when attached to the trigger module 1100, comprises a pistol grip that can enable a clinician to hold the handle 1000 in a way that positions the trigger module 1100 on top of the doctor's hand. The power module 1300, when attached to the drive module 1100, comprises an end grip that enables a clinician to hold the grip 1000 like a rod. The 1200 power module is longer than the 1300 power module, although the 1200 and 1300 power modules can comprise any suitable length. The 1200 Power Module has more battery cells than the 1300 Power Module and can adequately accommodate these additional battery cells due to its length. In many cases, the 1200 power module can supply more power to the module.
[0188] [0188] In many cases, in addition to the above, only one of the 1200 and 1300 power modules is coupled to the 1100 drive module at a time. In certain cases, the power module 1200 may be in the way when the drive shaft assembly 4000, for example, is attached to the drive module 1100. Alternatively, both the power modules 1200 and 1300 may be operatively coupled to the drive module 1100. 1100 drive module at the same time. In such cases, the drive module 1100 can access power supplied by both the power modules 1200 and 1300. Additionally, a clinician can switch between a pistol grip and a rod grip when both power modules 1200 and 1300 are attached to the drive module 1100. In addition, this arrangement enables the power module 1300 to act as a counterweight to a drive shaft assembly, such as the 2000, 3000, 4000, or 5000 drive shaft assemblies, for example, attached to the 1100 drive module.
[0189] [0189] With reference to Figures 7 and 8, the grip drive module 1100 additionally comprises a frame 1500, a motor assembly 1600, a drive system 1700 operatively coupled to the motor assembly 1600 and a control system 1800. frame 1500 comprises an elongated drive shaft that extends through the motor assembly 1600. The elongated drive shaft comprises a distal end 1510 and electrical contacts, or sockets, 1520 defined at the distal end 1510. Electrical contacts 1520 are in electrical communication with the 1100 drive module 1800 control system through one or more electrical circuits and are configured to transmit signals and/or power between the 1800 control system and the drive shaft assembly, such as 2000, 3000, 4000 or 5000 drive shaft, for example, fixed to the drive module
[0190] [0190] Referring to Figures 12 and 13, the motor assembly 1600 comprises an electric motor 1610 that includes a housing 1620, a drive shaft 1630 and a gear reduction system. The electric motor 1610 additionally comprises a stator that includes windings 1640 and a rotor that includes magnetic elements 1650.
[0191] [0191] The 1800 control system is in communication with the 1600 engine package and the 1100 drive module electrical power circuit. The 1800 control system is configured to control the power supplied to the 1600 engine package by the power circuit electric. The electrical power circuit is configured to provide a constant, or at least nearly constant, direct current (DC) voltage. In at least one case, the electrical power circuit supplies 3V direct current (DC) to the control system.
[0192] [0192] In addition to the above, again with reference to Figures 7 and 8, the drive system 1700 comprises a rotating drive shaft 1710 comprising a ribbed distal end 1720 and a longitudinal opening 1730 defined therein. The rotary drive shaft 1710 is operatively mounted to the output drive shaft of the 1600 motor assembly so that the rotary drive shaft 1710 rotates with the output drive shaft of the motor.
[0193] [0193] Similar to the above, the drive system 2700 comprises a swivel drive shaft 2710 that is operatively coupled to the swivel drive shaft 1710 of the handle 1000 when the drive shaft assembly 2000 is mounted on the drive module. drive 1100 so that drive shaft 2710 rotates with drive shaft 1710. For this purpose, drive shaft 2710 comprises a grooved proximal end 2720 which mates with grooved distal end 1720 of drive shaft 1710 so as to that the 1710 and 2710 drive shafts rotate together when the 1710 drive shaft is rotated by the motor assembly
[0194] [0194] As discussed above, with reference to Figures 3 to 8, the mounting interface 1130 of the 1110 drive module is configured to mate with a corresponding mounting interface on the 2000, 3000, 4000 and 4000 drive shaft assemblies. 5000, for example. For example, the drive shaft assembly 2000 comprises a mounting interface 2130 configured to be mated to the mounting interface 1130 of the drive module 1100. More specifically, the proximal portion 2100 of the drive shaft assembly 2000 comprises an enclosure 2110 that defines mounting interface 2130. Referring primarily to Figure 8, drive module 1100 comprises latches 1140 that are configured to releasably secure mounting interface 2130 of drive shaft assembly 2000 against the mounting interface 1130 of drive module 1100. When drive module 1100 and drive shaft assembly 2000 are joined along a longitudinal axis as described above, latches 1140 contact the drive interface 1140. 2130 mount and rotate out into an unlocked position. Referring primarily to Figures 8, 10 and 11, each latch 1140 comprises a locking end 1142 and a pivot portion 1144. The pivot portion 1144 of each latch 1140 is pivotally coupled to the drive module housing 1110.
[0195] [0195] In addition to the above, bias springs 1146 hold latches 1140 in their locked positions. The distal ends 1142 are sized and configured to prevent, or at least inhibit, relative longitudinal movement, i.e., translation along a longitudinal axis, between the drive shaft assembly 2000 and the drive module. drive 1100 when latches 1140 are in their locked positions. In addition, latches 1140 and latch windows 1240 are sized and configured to prevent relative lateral movement, i.e., transverse translation along the longitudinal axis, between drive shaft assembly 2000 and drive module 1100. In addition In addition, the latches 1140 and the latch windows 2140 are sized and configured to prevent the drive shaft assembly 2000 from rotating with respect to the drive module 1100. The drive module 1100 additionally comprises release actuators 1150 which , when pressed by a physician, move the latches from their locked positions to their unlocked positions. Actuation module 1100 comprises a first release actuator 1150 slidably mounted in an opening defined in the first side of the handle housing 1110 and a second release actuator 1150 slidably mounted in an opening defined in a second side, or opposite side of the 1110 handle housing. Although the 1150 release actuators can be actuated separately, both 1150 release actuators typically need to be pressed to fully unlock the 2000 drive shaft assembly from the 1100 drive module and allow that the drive shaft assembly 2000 is separate from the drive module 1100. That said, it is possible that the drive shaft assembly 2000 can be separated from the drive module 1100 when only one release actuator 1150 is pressed.
[0196] [0196] After drive shaft assembly 2000 has been attached to handle 1000 and end actuator 7000 has been mounted to drive shaft 2000, the clinician can maneuver handle 1000 to insert end actuator 7000 into a patient. In at least one instance, the end actuator 7000 is inserted into the patient through a trocar and then manipulated to position the jaw assembly 7100 of the end actuator assembly 7000 in relation to the patient's tissue. Often, the 7100 jaw assembly needs to be in its closed configuration, or clamped, in order to fit through the trocar. Once fitted through the trocar, the 7100 jaw assembly can be opened so that the patient's tissue fits between the jaws of the 7100 jaw assembly. At this point, the 7100 jaw assembly can be returned to its original position. closed configuration to hold the patient's tissue between the jaws. The grip force applied to the patient's tissue by the 7100 gripper assembly is sufficient to move or otherwise manipulate tissue during a surgical procedure. Thereafter, the 7100 jaw assembly can be reopened to release the patient's tissue from the 7000 end actuator. This process can be repeated until it is desirable to remove the 7000 end actuator from the patient. At this point, the jaw assembly 7100 can be returned to its closed configuration and retracted through the trocar. Other surgical techniques are envisioned in which the 7000 end actuator is inserted into a patient through an open incision, or without the use of a trocar. In any event, it is anticipated that the gripper assembly 7100 may have to be opened and closed several times during a surgical technique.
[0197] [0197] Again with reference to Figures 3 to 6, the drive shaft assembly 2000 additionally comprises a gripping trigger system 2600 and a control system 2800. The gripping trigger system 2600 comprises a gripping trigger 2610 connected in swivel mode to the 2110 proximal housing of the 2000 drive shaft assembly. As discussed below, the 2610 grip trigger drives the 1610 motor to operate the 7000 end actuator gripper drive when the 2610 grip trigger is acted. Gripping trigger 2610 comprises an elongated portion that can be grasped by the clinician while holding the handle 1000. Gripping trigger 2610 further comprises a mounting portion 2620 that is pivotally connected to a mounting portion 2120 of the cabinet. proximal 2110 so that the gripping trigger 2610 is rotatable about a fixed or at least substantially fixed axis. Closing trigger 2610 is pivotable between a distal position and proximal position, with the proximal position of closing trigger 2610 being closer to the pistol grip 1000 than the distal position. Closing trigger 2610 further comprises a tab 2615 extending therefrom that pivots within proximal housing 2110. When closing trigger 2610 is in its distal position, tab 2615 is positioned above but not in contact with, a 2115 switch mounted in the 2110 proximal cabinet. The 2115 switch is part of an electrical circuit configured to sense the actuation of the 2610 close trigger which is in an open condition when the 2610 close trigger is in your open position. When closing trigger 2610 is moved to its proximal position, tab 2615 contacts switch 2115 and closes the electrical circuit. In various cases, switch 2115 may comprise a toggle switch, for example, which is mechanically toggled between open and closed states when it contacts tab 2615 of closing trigger 2610. In certain cases, switch 2115 it may comprise a proximity sensor, for example, and/or any suitable type of sensor. In at least one case, the switch 2115 comprises a Hall effect sensor that can detect the amount by which the closing trigger 2610 has been turned and, based on the amount of rotation, control the speed at which the motor 1610 is operated. In such cases, higher speeds of the 2610 close trigger result in higher speeds of the 1610 motor while lower speeds result in lower speeds, for example. In either case, the electrical circuit is in communication with the control system 2800 of the drive shaft assembly 2000, which is discussed in more detail below.
[0198] [0198] In addition to the above, the control system 2800 of the drive shaft assembly 2000 comprises a printed circuit board (PCB) 2810, at least one microprocessor 2820, and at least one memory device 2830. Plate 2810 may be rigid and/or flexible and may comprise any suitable number of layers. The 2820 microprocessor and the 2830 memory device are part of a control circuit defined on the 2810 board that communicates with the control system 1800 of the handle 1000. The drive shaft assembly 2000 additionally comprises a signal communication system. 2900 and handle 1000 additionally comprise a signal communication system 1900 which are configured to transmit data between the drive shaft control system 2800 and the handle control system 1800. The signal communication system 2900 is configured to transmit data to the 1900 signal communication system using any suitable analog and/or digital components. In many cases, the 2900 and 1900 communication systems can communicate through the use of a plurality of distinct channels that allow the 1820 microprocessor input ports to be directly controlled, at least in part, by the input ports of the 1820 microprocessor. 2820 microprocessor output. In some cases, the 2900 and 1900 communication systems may use multiplexing. In at least one such example, the control system 2900 includes a multiplexing device that sends multiple signals on a carrier channel at the same time as a single complex signal to a multiplexing device of the control system 1900 that recovers the signals separated from the complex signal.
[0199] [0199] The 2900 communication system comprises an electrical connector 2910 mounted on the circuit board 2810. The electrical connector 2910 comprises a connector body and a plurality of electrically conductive contacts mounted on the connector body. Electrically conductive contacts comprise male pins, for example, which are soldered into electrical paths defined on the 2810 circuit board. In other cases, male pins may be in communication with circuit board paths through sockets with zero insertion force (ZIF -
[0200] [0200] As discussed above, the control system 1800 of the handle 1000 is in communication with, and is configured to control, the electrical power circuit of the handle 1000. The control system of the handle 1800 is also powered by the handle 1000.
[0201] [0201] In addition to the above, the actuation of the 2610 grip trigger is detected by the 2800 drive shaft control system and communicated to the 1800 grip control system through the 2900 and 1900 communication systems. Upon receiving a signal that the 2610 grip trigger has been actuated, the 1800 grip control system supplies power to the 1610 electric motor of the 1600 power pack to turn the 1710 drive shaft of the 1700 grip drive system, and the 2710 drive shaft of the 2700 drive shaft drive system, in a direction that closes the 7100 jaw assembly of the 7000 end actuator. The mechanism for converting the rotation of the 2710 drive shaft into motion closure of the 7100 grip assembly is discussed in more detail below. While grip trigger 2610 is held in its actuated position, electric motor 1610 will rotate drive shaft 1710 until gripper assembly 7100 reaches its fully tightened position. When the 7100 grip assembly reaches its fully tightened position, the 1800 grip control system cuts off electrical power to the 1610 electric motor. The 1800 grip control system can determine when the 7100 grip assembly reaches He made his position completely tight in any suitable way. For example, the grip control system 1800 may comprise an encoder system that monitors the rotation of, and counts the revolutions of, the output drive shaft of the electric motor 1610, and once the number of revolutions reaches a predetermined limit, the system - 1800 grip control theme may interrupt power supply to the 1610 electric motor. In at least one case, the 7000 end actuator assembly may comprise one or more sensors configured to detect when the 7100 grip assembly has reached its completely tight position. In at least one of these cases, the sensors on the 7000 end actuator are in signal communication with the 1800 grip control system via electrical circuits that extend through the 2000 drive shaft assembly that may include electrical contacts 1520 and 2520, for example.
[0202] [0202] When the 2610 grip trigger is rotated distally out of its proximal position, the 2115 switch is opened, which is sensed by the 2800 drive shaft control system and communicated to the 1800 grip control system through the systems 2900 and 1900 communication switches. Upon receiving a signal that the 2610 grip trigger has been moved out of its actuated position, the 1800 grip control system reverses the polarity of the voltage differential that is applied to the 1610 electric motor of the motor assembly 1600 to rotate the drive shaft 1710 of the handle drive system 1700, and the drive shaft 2710 of the drive shaft drive system 2700, in an opposite direction which, as a result, opens the gripper assembly 7100 the 7000 end actuator. When the 7100 grip assembly reaches its fully open position, the 1800 grip control system cuts off electrical power to the 1610 electric motor. the 1800 grip control can determine when the 7100 grip assembly has reached its fully open position in any suitable way. For example, the 1800 grip control system may utilize the encoder system and/or the one or more sensors described above to determine the configuration of the 7100 grip assembly. In view of the above, the clinician needs to be attentive when holding the trigger. 2610 grip assembly in its actuated position in order to hold the 7100 grip assembly in its gripped configuration as otherwise the 1800 control system will open the 7100 grip assembly. With this in mind, the drive shaft assembly 2000 additionally comprises an actuator latch 2630 configured to releasably lock the gripping trigger 2610 in its actuated position to prevent accidental opening of the jaw assembly 7100. The actuator latch 2630 can be manually released, or otherwise released, by the clinician to enable the 2610 trigger to be rotated distally and open the 7100 jaw assembly.
[0203] [0203] The grip trigger system 2600 additionally comprises a resilient biasing member, such as a torsion spring, for example, configured to resist closing of the grip trigger system 2600. The torsion spring may also help reduce and/or mitigate jerking and/or flickering of the 2610 grip trigger. This torsion spring can also automatically return the 2610 grip trigger to its non-actuated position when the 2610 grip trigger is released. The 2630 actuator lock discussed above can adequately hold the 2610 gripping trigger in its actuated position against the biasing force of the torsion spring.
[0204] [0204] As discussed above, control system 1800 operates electric motor 1610 to open and close jaw assembly 7100. Control system 1800 is configured to open and close jaw assembly 7100 at the same speed. In these cases, the 1800 control system applies the same voltage pulses to the 1610 electric motor, albeit with different voltage polarities, when opening and closing the 7100 grip assembly. That said, the 1800 control system can be configured to open and close the 7100 grip assembly at different speeds. For example, the 7100 gripper assembly can be closed at a first speed and opened at a second speed that is faster than the first speed. In these cases, the slower closing speed provides the clinician with the opportunity to better position the 7100 Clamp Assembly while the tissue is clamped. Alternatively, the 1800 control system can open the 7100 jaw assembly at a slower speed. In these cases, the slower opening speed minimizes the possibility that the jaws being opened will collide with adjacent tissue. In either case, the 1800 control system can decrease the duration of voltage pulses and/or increase the distance between voltage pulses to slow down and/or speed up the movement of the 7100 grip assembly.
[0205] [0205] As discussed above, the control system 1800 is configured to interpret the position of the grip trigger 2610 as a command to position the gripper assembly 7100 in a specific configuration. For example, the 1800 control system is configured to interpret the most proximal position of the 2610 grip trigger as a command to close the 7100 jaw assembly and any other grip trigger position as a command to open the grip assembly. That said, the 1800 control system can be configured to interpret the position of the 2610 grip trigger in a proximal range of positions, rather than a single position, as a command to close the 7100 grip assembly. This arrangement may enable the 7000 gripper set to be more responsive to the physician's action. In such cases, the 2610 grip trigger's range of motion is divided into ranges - a proximal range which is interpreted as a command to close the 7100 jaw assembly and a distal range which is interpreted as a command to open the 7100 jaw assembly. In at least one case, the range of motion of the 2610 grip trigger may have an intermediate range between the proximal range and the distal range. When the 2610 grip trigger is in the mid-range, the 1800 control system may interpret the position of the 2610 grip trigger as a command to neither open nor close the 7100 jaw assembly. possibility of flickering between opening and closing ranges. In the cases described above, the 1800 control system can be configured to ignore cumulative commands to open or close the 7100 jaw assembly. For example, if the 2610 Closing Trigger has already been fully retracted to its most proximal position , the control assembly 1800 can ignore the movement of the grip trigger 2610 in the proximal, or gripping range, until the gripping trigger 2610 enters the distal or opening range, at which point the control system 1800 can then actuate electric motor 1610 to open jaw assembly 7100.
[0206] [0206] In certain cases, in addition to the above, the position of the grip trigger 2610 within the grip trigger range, or at least a portion of the grip trigger range, may enable the clinician to control the motor speed 1610 and thus the speed at which the 7100 grip assembly is opened or closed by the 1800 control assembly. In at least one case, the 2115 sensor comprises a Hall effect sensor, and/or any other sensor suitable, configured to sense the position of the grip trigger 2610 between its non-actuated distal position and its fully actuated proximal position. The Hall Effect Sensor is configured to transmit a signal to the 1800 Handle Control System through the 2800 Drive Shaft Control System so that the 1800 Handle Control System can control the speed of the 1610 Electric Motor in response to the grip trigger position 2610. In at least one case, the grip control system 1800 controls the speed of the electric motor 1610 proportionally, or linearly, to the position of the grip trigger 2610. For example, if the 2610 grip trigger is moved halfway along its range, then the 1800 grip control system will operate the 1610 electric motor at half the speed at which the electric motor
[0207] [0207] As described above, the 2610 gripping trigger is movable to operate the 1610 electric motor to open or close the 7000 end actuator jaw assembly 7100. The 1610 electric motor is also operable to rotate the 7000 end actuator in around a longitudinal axis and pivot the end actuator 7000 with respect to the elongated drive shaft 2200 at the pivot joint 2300 of the drive shaft assembly 2000. Referring primarily to Figures 7 and 8, the drive module drive 1100 comprises an input system 1400 that includes a rotation actuator 1420 and a pivot actuator 1430. The input system 1400 further comprises a printed circuit board (PCB) 1410 which is in communication signal with the 1810 printed circuit board (PCB) of the 1800 control system. The 1100 drive module comprises an electrical circuit, such as a wiring harness or flexible electrical tape, for example, enabling the 1400 input system to communicate with the 1800 control system. The 1420 rotation actuator is rotatably supported in the 1110 cabinet and is in signal communication with the 1410 input board and/or the 1810 control board, as described in more detail below. The 1430 articulation actuator is supported by and in signal communication with the 1410 input board and/or the 1810 control board, as described in more detail below.
[0208] [0208] Referring primarily to Figures 8, 10 and 11, in addition to the above, the grip housing 1110 comprises an annular groove or slot defined therein adjacent to the distal mounting interface 1130. The rotation actuator 1420 comprises a annular ring 1422 rotatably supported within the annular groove and, due to the configuration of the side walls of the annular groove, the annular ring 1422 is prevented from translating longitudinally and/or laterally with respect to the grip housing 1110. The ring ring 1422 is rotatable in a first direction, or clockwise, and in a second direction, or counterclockwise, about a longitudinal axis that extends through the drive module frame 1500
[0209] [0209] In various embodiments, in addition to the above, the first and second sensors may comprise switches that can be mechanically closed by the annular ring detectable element 1422. When the annular ring 1422 is rotated in the first direction from a central position, the detectable element closes the switch of the first sensor. When the first sensor switch is closed, the control system 1800 operates the electric motor 1610 to rotate the end actuator 7000 in the first direction. When annular ring 1422 is rotated in the second direction to the center position, the detectable element is disengaged from the first key and the first key is reopened. As soon as the first switch is reopened, the 1800 control system cuts power to the 1610 electric motor to stop the rotation of the 7000 end actuator. Similarly, the detectable element closes the second sensor switch when the annular ring 1422 is rotated in the second direction from the center position. When the second sensor switch is closed, the 1800 control system operates the 1610 electric motor to rotate the 7000 end actuator in the second direction. When annular ring 1422 is rotated in the first direction to the center position, the detectable element is disengaged from the second key and the second key is reopened. As soon as the second switch is reopened, the control system 1800 cuts power to the electric motor 1610 to stop the rotation of the end actuator 7000.
[0210] [0210] In various embodiments, in addition to the above, the first and second rotation actuator sensors 1420 comprise proximity sensors, for example.
[0211] [0211] In addition to the above, the rotation actuator 1420 may comprise one or more springs configured to center, or at least substantially center, the rotation actuator 1420 when it is released by the clinician. In these cases, the springs can act to shut off the 1610 electric motor and stop the end actuator from rotating.
[0212] [0212] In view of the foregoing, the reader will understand that the gripping trigger 2610 and the rotation actuator 1420 are both intended to rotate the drive shaft 2710 and, respectively, operate the gripper assembly 7100 or rotate the end actuator 7000. The system that uses the rotation of the 2710 drive shaft to selectively perform these functions is described in more detail below.
[0213] [0213] Referring to Figures 7 and 8, the articulation actuator 1430 comprises a first push button 1432 and a second push button 1434. The first push button 1432 is part of a first articulation control circuit and the second Pushbutton 1434 is part of a second linkage circuit of input system 1400. First pushbutton 1432 comprises a first key that is closed when first pushbutton 1432 is pressed. The 1800 grip control system is configured to detect the closing of the first switch and, in addition, the closing of the first linkage control circuit. When the 1800 Handle Control System detects that the first linkage control circuit has closed, the 1800 Handle Control System operates the 1610 electric motor to link the 7000 end actuator in a first linkage direction to the around the hinge joint 2300. When the first push button 1432 is released by the clinician, the first hinge control circuit is opened which, once detected by the control system 1800, causes the control system 1800 to cut power to the 1610 electric motor to stop the 7000 end actuator linkage.
[0214] [0214] In many cases, in addition to the above, the articulation range of the 7000 end actuator is limited and the 1800 control system can use the encoder system discussed above for monitoring.
[0215] [0215] Similar to the above, the second pushbutton 1434 comprises a second switch that is closed when the second pushbutton 1434 is pressed. The 1800 grip control system is configured to detect the closing of the second switch and, in addition, the closing of the second linkage control circuit. When the 1800 Handle Control System detects that the second linkage control circuit has closed, the 1800 Handle Control System operates the 1610 electric motor to link the 7000 end actuator in a second direction around the linkage joint.
[0216] [0216] In many cases, the articulation range of the 7000 end actuator is limited and the 1800 control system can use the encoder system discussed above to monitor the rotational output of the 1610 electric motor, for example to monitor the amount, or degree, by which the 7000 end actuator is rotated in the second direction. In addition to or in lieu of the encoder system, the drive shaft assembly 2000 may comprise a second sensor configured to detect when the end actuator 7000 has reached its articulation limit in the second direction. In either case, when the 1800 control system determines that the 7000 end actuator has reached the linkage limit in the second direction, the 1800 control system may cut power to the 1610 electric motor to stop the actuator linkage. end 7000.
[0217] [0217] As described above, the 7000 end actuator is pivotable in a first direction (Figure 16) and/or in a second direction (Figure 17) from a central or non-hinged position (Figure 15) . After the 7000 End Actuator has been pivoted, the clinician may attempt to re-center the 7000 End Actuator through the use of the 1432 First and Second Pivot Push Buttons and
[0218] [0218] In addition to or in lieu of the above, the 1800 Handle Control System may be configured to re-center the 7000 End Actuator. In at least one of these cases, the 1800 Handle Control System may re-center the 7000 end actuator when both linkage buttons 1432 and 1434 of the linkage actuator 1430 are pressed at the same time. When the 1800 grip control system comprises an encoder system configured to monitor the rotational output of the 1610 electric motor, for example, the 1800 grip control system can determine the amount and direction of articulation needed to re-center 7000 end actuator. In various cases, the 1400 input system may comprise a home button, for example, which, when pressed, automatically centers the 7000 end actuator.
[0219] [0219] Referring primarily to Figures 5 and 6, the elongated drive shaft 2200 of the drive shaft assembly 2000 comprises an outer cabinet, or tube, 2210 mounted to the proximal cabinet 2110 of the proximal portion 2100. The outer cabinet 2210 com- comprises a longitudinal opening 2230 that extends therethrough and a proximal flange 2220 that secures the outer housing 2210 to the proximal housing 2110. The frame 2500 of the drive shaft assembly 2000 extends through the longitudinal opening 2230 of the drive shaft. 2200. More specifically, the drive shaft 2510 of the drive shaft structure 2500 narrows to become a smaller drive shaft 2530 that extends through the longitudinal opening 2230. That said, the drive shaft structure 2230 is naming 2500 may comprise any suitable arrangement. The drive system 2700 of the drive shaft assembly 2000 also extends through the longitudinal opening 2230 of the elongated drive shaft 2200. More specifically, the drive shaft 2710 of the drive shaft drive system 2700 narrows. until it becomes a minor drive shaft 2730 which extends through the longitudinal opening 2230. That said, the drive shaft drive system 2700 may comprise any suitable arrangement.
[0220] [0220] Referring primarily to Figures 20, 23, and 24, the outer casing 2210 of the elongated drive shaft 2200 extends to the pivot joint 2300. The pivot joint 2300 comprises a proximal frame 2310 mounted in the outer casing. 2210 so that there is little, if any, translation and/or relative rotation between the proximal frame 2310 and the outer cabinet 2210. Referring primarily to Figure 22, the proximal structure 2310 comprises an annular portion 2312 mounted on the side wall of the outer cabinet 2210 and tabs 2314 extending distally from the annular portion
[0221] [0221] Referring primarily to Figures 20, 23, and 24, the outer housing 2410 of the distal attachment portion 2400 comprises a longitudinal opening 2439 extending therethrough. Longitudinal opening 2430 is configured to receive a proximal attachment portion 7400 of end actuator 7000. End actuator 7000 comprises an outer housing 6230 that is closely received within longitudinal aperture 2430 of distal attachment portion 2400 so that there is little, if any, relative radial movement between the proximal attachment portion 7400 of the end actuator 7000 and the distal attachment portion 2400 of the drive shaft assembly 2000. The proximal attachment portion 7400 further comprises an annular assembly of lock notches 7410 defined in outer housing 6230 that is releasably engaged by a 6400 end actuator latch on distal attachment portion 2400 of drive shaft assembly 2000. When the end actuator latch 6400 is engaged with the 7410 latch notches, the 6400 end actuator latch prevents, or at least inhibits, relative longitudinal movement between the the proximal attachment portion 7400 of the end actuator 7000 and the distal attachment portion 2400 of the drive shaft assembly 2000. As a result of the above, only the relative rotation between the proximal attachment portion 7400 of the end actuator 7000 and distal attachment portion 2400 of drive shaft assembly 2000 is permitted. For this purpose, the outer housing 6230 of the end actuator 7000 is received closely within the longitudinal opening 2430 defined in the distal attachment portion 2400 of the drive shaft assembly 2000.
[0222] [0222] In addition to the above, with reference to Figure 21, the outer cabinet 6230 additionally comprises an annular slot, or recess, 6270 defined therein that is configured to receive a sealing ring 6275 therein. O-ring 6275 is compressed between outer housing 6230 and the side wall of longitudinal opening 2430 when end actuator 7000 is inserted into distal attachment portion 2400. O-ring 6275 is configured to resist, but allow, the relative rotation between the end actuator 7000 and the distal attachment portion 2400 so that the O-ring 6275 can prevent, or minimize the possibility of, unintended relative rotation between the end actuator 7000 and the attachment portion 2400. In many cases, the O-ring 6275 may provide a seal between the end actuator 7000 and the distal attachment portion 2400 to prevent, or at least minimize the possibility of fluid ingress into the drive shaft assembly. 2000, for example.
[0223] [0223] Referring to Figures 14 through 21, the jaw assembly 7100 of the end actuator 7000 comprises a first jaw 7110 and a second jaw 7120. Each jaw 7110, 7120 comprises a distal end that is configured to assist a physician in tissue dissection with the end actuator 7000. Each gripper 7110, 7120 further comprises a plurality of teeth that are configured to assist a physician in gripping and maintaining tissue with the end actuator 7000. Furthermore, referring primarily to Figure 21, each jaw 7110, 7120 comprises a proximal end, i.e., proximal ends 7115, 7125, respectively, which pivotally connect the jaws 7110, 7120 together. Each proximal end 7115, 7125 comprises an opening extending therethrough that is configured to closely receive a pin 7130 therein. Pin 7130 comprises a central body 7135 closely received within openings defined at proximal ends 7115, 7125 of jaws 7110, 7120 so that there is little, if any, relative translation between jaws 7110, 7120 and pin 7130. Pin 7130 defines a J-shaped jaw geometry axis around which jaws 7110, 7120 can be rotated and also pivotally mounts jaws 7110, 7120 in the 7000 end actuator outer case 6230. More specifically , outer housing 6230 comprises distally extending tabs 6235 that have openings defined therein that are also configured to closely receive pin 7130 so that jaw assembly 7100 does not translate with respect to a drive shaft portion 7200 of the 7000 end actuator. The 7130 pin additionally comprises enlarged ends that prevent the jaws 7110, 7120 from being separated from the 7130 pin and also prevents the jaw assembly 7100 is separate from the drive shaft portion 7200. This arrangement defines a pivot joint 7300.
[0224] [0224] Referring primarily to Figures 21 and 23, the 7110 and 7120 jaws are pivotable between their open and closed positions by a jaw assembly drive that includes 7140 drive links, a 7150 drive nut, and a 7140 drive nut. drive screw 6130. As described in more detail below, the drive screw 6130 is selectively rotatable by the drive shaft 2730 of the drive shaft 2700 drive system. The drive screw 6130 comprises an annular flange 6132 which is received closely spaced within a slot, or groove, 6232 (Figure 25) defined in the outer housing 6230 of the end actuator 7000. The side walls of slot 6232 are configured to prevent, or at least inhibit, longitudinal and/or radial translation between the drive screw 6130 and the outer case 6230, but still allow relative rotational movement between the lead screw 6130 and the outer case 6230. The lead screw 6130 comprises additionally a threaded end 6160 which is threadably engaged with a threaded opening 7160 defined in the drive nut. The drive nut 7150 is prevented from turning with the drive screw 6130 and, as a result, the drive nut 7150 is translated when the drive bolt 6130 is turned. In use, drive screw 6130 is rotated in a first direction to displace drive nut 7150 proximally and in a second, or opposite direction, to displace drive nut 7150 distally. The drive nut 7150 further comprises a distal end 7155 that comprises an opening defined therein that is configured to closely receive pins 7145 extending from the drive connections.
[0225] [0225] As discussed above, the 1800 control system is configured to actuate the 1610 electric motor to perform three different functions of the end actuator - clamp/open the 7100 jaw assembly (Figures 14 and 15), rotate the actuator end actuator 7000 around a longitudinal axis (Figures 18 and 19), and pivot the end actuator 7000 around a pivot axis (Figures 16 and 17). Referring primarily to Figures 26 and 27, the 1800 control system is configured to operate a 6000 transmission to selectively perform these three end actuator functions. The 6000 transmission comprises a 6100 first clutch system configured to selectively transmit the rotation of the 2730 drive shaft to the drive screw.
[0226] [0226] In several cases, in addition to the above, the drive shaft 2510 and/or the drive shaft 1510 comprises a flexible circuit that includes electrical tracks that form part of the clutch control circuits. The flexible circuit may comprise a tape, or substrate, with conductive pathways defined in and/or on it. The flexible circuit may also comprise sensors and/or any solid state component, such as signal smoothing capacitors, for example, mounted thereon. In at least one case, each of the conductive routes may comprise one or more signal smoothing capacitors which can, among other things, balance out fluctuations in signals transmitted through the conductive routes. In many cases, the flexible circuit may be coated with at least one material, such as an elastomer, for example, which can seal the flexible circuit against ingress of fluid.
[0227] [0227] Referring primarily to Figure 28, the first clutch system 6100 comprises a first clutch 6110, a first expandable drive ring 6120, and a first electromagnetic actuator 6140. The first clutch 6110 comprises an annular ring and is slidably arranged over drive shaft 2730. The first clutch 6110 comprises a magnetic material and is movable between a disengaged or non-actuated position (Figure 28) and an engaged or actuated position (Figure 29) by electromagnetic fields EF generated by the first electro-magnetic actuator 6140. In several cases, the first clutch 6110 is at least partially comprised of iron and/or nickel, for example. In at least one case, the first clutch 6110 comprises a permanent magnet. As illustrated in Figure 22A, drive shaft 2730 comprises one or more longitudinal key slots 6115 defined therein that are configured to prevent longitudinal movement of clutch 6110 with respect to drive shaft 2730. More specifically, the clutch 6110 comprises one or more keys that extend into the key slots 6115 so that the distal ends of the key slots 6115 stop the distal movement of the clutch 6110 and the proximal ends of the key slots 6115 stop the movement. proximal movement of the 6110 clutch.
[0228] [0228] When the first clutch 6110 is in its disengaged position (Figure 28), the first clutch 6110 rotates with the drive shaft 2130 but does not transmit rotary motion to the first drive ring 6120. As can be seen in Figure 28 , first jaw 6110 is separate from, or not in contact with, first drive ring 6120. As a result, rotation of drive shaft 2730 and first clutch 6110 is not transmitted to drive screw 6130 when the first set of clutch 6100 is in its disengaged state. When first clutch 6110 is in its engaged position (Figure 29), first clutch 6110 is engaged with first drive ring 6120 so that first drive ring 6120 is expanded, or extended, radially outward to enter in contact with drive screw 6130. In at least one case, the first drive ring 6120 comprises an elastomeric band, for example. As can be seen in Figure 29, the first drive ring 6120 is pressed against an annular inner side wall 6135 of the drive screw 6130. As a result, the rotation of the drive shaft 2730 and the first clutch 6110 is transmitted to the stop. 6130 drive spindle when the 6100 first clutch assembly is in its engaged state. Depending on the direction in which the drive shaft 2730 is rotated, the first clutch assembly 6100 may move the jaw assembly 7100 to its open and closed configurations when the first clutch assembly 6100 is in its engaged state.
[0229] [0229] As described above, the first 6140 electromagnetic actuator is configured to generate magnetic fields to move the first 6110 clutch between its disengaged (Figure 28) and engaged (Figure 29) positions. For example, with reference to Figure 28, the first electromagnetic actuator 6140 is configured to emit an EFL magnetic field that repels, or drives, the first clutch 6110 in the opposite direction to the first drive ring 6120 when the first clutch assembly 6100 it is in its disengaged state. The first electromagnetic actuator 6140 comprises one or more coils wound in a cavity defined in the drive shaft structure 2530 that generates the EFL magnetic field when current flows in a first direction through a first electrical clutch circuit including the coils wound. .
[0230] [0230] In addition to the above, with reference to Figure 29, the first electromagnetic actuator 6140 is configured to emit an EFD magnetic field that pulls, or actuates, the first clutch 6110 towards the first drive ring 6120 when the first 6100 clutch assembly is in its engaged state. The coils of the first 6140 electromagnetic actuator generate the EFD magnetic field when current flows in a second, or opposite direction, through the first electric clutch circuit. The 1800 control system is configured to apply an opposite polarity of voltage to the first electrical clutch circuit to create current flowing in the opposite direction. The 1800 control system can continuously apply opposite polarity voltage to the first electric clutch circuit to continuously maintain the 6110 first clutch in its engaged position and maintain operational engagement between the 6120 first drive ring and the stop. 6130 drive spindle. Alternatively, the 6110 first clutch can be configured to be compressed within the 6120 first drive ring when the 6110 first clutch is in its engaged position, in which case the 1800 control system may not need continuously applying a voltage polarity to the first electric clutch circuit to maintain the first clutch assembly 6100 in its engaged state. In such cases, the control system 1800 may stop applying voltage polarity once the first clutch 6110 has been sufficiently compressed in the first drive ring 6120.
[0231] [0231] Notably, in addition to the above, the 6150 first clutch lock is also configured to lock the clutch assembly actuation when the 6110 first clutch is in its disengaged position. More specifically, referring again to Figure 28, the first clutch 6110 pushes the first clutch lock 6150 on the drive screw 6130 into engagement with the outer case 6230 of the end actuator 7000 when the first clutch 6110 is in its position. disengaged so that the drive screw 6130 does not rotate, or at least rotates substantially, with respect to the outer case 6230. The outer case 6230 comprises a slot 6235 defined therein that is configured to receive the first clutch latch 6150. When the first clutch 6110 is moved to its engaged position, with reference to Figure 29, the 6110 first clutch is no longer engaged with the 6150 first clutch latch, and as a result, the 6150 first clutch latch is no longer prone to engagement with the 6230 outer case and the 6130 drive screw can rotate freely with respect to the 6230 outer case. As a result of the above, the 6110 first clutch can Do at least two things - operate the clutch drive when the first 6110 clutch is in its engaged position and lock the clutch drive when the first 6110 clutch is in its disengaged position.
[0232] [0232] Additionally, in addition to the above, the threads of the threaded portions 6160 and 7160 can be configured to prevent, or at least resist, the reverse drive of the gripper drive. In at least one example, the pitch and/or thread angle of the threaded portions 6160 and 7160, for example, may be selected to prevent reverse drive or unintentional opening of the jaw assembly 7100. As a result of the foregoing , the possibility of the 7100 jaw assembly opening or closing unintentionally is prevented, or at least reduced.
[0233] [0233] Referring primarily to Figure 30, the second clutch system 6200 comprises a second clutch 6210, a second expandable drive ring 6220, and a second electromagnetic actuator 6240. The second clutch 6210 comprises an annular ring and is arranged so that Sliding way on the drive shaft
[0234] [0234] When the second clutch 6210 is in its disengaged position, with reference to Figure 30, the second clutch 6210 rotates with the drive shaft 2730 but does not transmit rotary motion to the second drive ring 6220. As can be seen from Figure 30, the second 6210 clutch is separated from, or not in contact with,
[0235] [0235] As described above, the second electromagnetic actuator 6240 is configured to generate magnetic fields to move the second clutch 6210 between its disengaged (Figure 30) and engaged (Figure 31) positions. For example, the second electromagnetic actuator 6240 is configured to emit an EFL magnetic field that repels, or drives, the second clutch 6210 in the opposite direction to the second drive ring 6220 when the second clutch assembly 6200 is in its disengaged state. The 6240 second electromagnetic actuator comprises one or more coils wound in a cavity defined in the 2530 drive shaft structure that generates the EFL magnetic field when current flows in a first direction through a second electrical clutch circuit including the wound coils.
[0236] [0236] In addition to the above, with reference to Figure 31, the second electromagnetic actuator 6240 is configured to emit an EFD magnetic field that pulls, or actuates, the second clutch 6210 toward the second drive ring 6220 when the - second clutch assembly 6200 is in its engaged state. The coils of the second 6240 electromagnetic actuator generate the EFD magnetic field when current flows in a second, or opposite direction, through the second electrical drive shaft circuit. The 1800 control system is configured to apply opposite voltage polarity to the second electrical drive shaft circuit to create current flowing in the opposite direction. The 1800 control system can continuously apply the opposite voltage polarity to the second electrical drive shaft circuit to continuously hold the 6210 second clutch in its engaged position and maintain operational engagement between the 6220 second drive ring and the clutch. 6230. Alternatively, the second clutch 6210 may be configured to be compressed within the second drive ring 6220 when the second clutch 6210 is in its engaged position, in which case the control system 1800 may not need to continuously apply a polarity. voltage to the second driveshaft electrical circuit to maintain the second 6200 clutch assembly in its engaged state. In such cases, the control system 1800 may stop applying voltage polarity once the second clutch 6210 has been sufficiently compressed on the second drive ring 6220.
[0237] [0237] Notably, in addition to the above, the second clutch lock 6250 is also configured to lock the rotation of the end actuator 7000 when the second clutch 6210 is in its disengaged position. More specifically, referring back to Figure 30, the second clutch 6210 pushes the second clutch latch 6250 on the outer drive shaft 6230 into engagement with the pivot link 2340 when the second clutch 6210 is in its disengaged position so that the actuator end cap 7000 does not rotate, or at least rotates substantially, with respect to the distal attachment portion 2400 of the drive shaft assembly 2000. As illustrated in Figure 27, the second clutch latch 6250 is positioned or compressed into a slot. , or channel, 2345 defined in the pivot link 2340 when the second clutch 6210 is in its disengaged position. As a result of the foregoing, the possibility for the end actuator 7000 to open or close unintentionally is prevented, or at least reduced. Also, as a result of the above, the second clutch 6210 can do at least two things - operate the end actuator rotation drive when the second clutch 6210 is in its engaged position and lock the end actuator rotation drive when the second 6210 clutch is in its disengaged position.
[0238] [0238] Referring primarily to Figures 22, 24 and 25, the drive shaft assembly 2000 additionally comprises a pivot drive system configured to pivot the distal attachment portion 2400 of the end actuator 7000 at the swivel joint. linkage 2300. The linkage drive system comprises a linkage drive 6330 pivotally supported within the distal attachment portion 2400. That said, the linkage drive 6330 is closely received within the distal attachment portion 2400 so that the pivot drive 6330 does not translate, or at least substantially translates, with respect to the distal attachment portion 2400. The pivot drive system of the drive shaft assembly 2000 further comprises a stationary gear 2330 fixedly mounted to the frame. 2310 pivot gear. More specifically, the 2330 stationary gear is fixedly mounted to a pin that connects one to the other. ba 2314 of the hinge frame 2310 and the hinge link 2340 so that the stationary gear 2330 does not rotate with respect to the hinge frame 2310. The stationary gear 2330 comprises a central body 2335 and an annular set of stationary teeth 2332 that extends around the perimeter of the central body 2335. The linkage drive 6330 comprises an annular set of drive teeth 6332 that are meshedly engaged with the stationary teeth 2332. When the linkage drive 6330 is rotated, the linkage drive 6330 is rotated. pivot 6330 pushes stationary gear 2330 and pivots distal attachment portion 2400 of drive shaft assembly 2000 and end actuator about swivel joint 2300.
[0239] [0239] Referring primarily to Figure 32, the third clutch system 6300 comprises a third clutch 6310, a third expandable drive ring 6320, and a third electromagnetic actuator 6340. The third clutch 6310 comprises an annular ring and is arranged so that Sliding way on the drive shaft
[0240] [0240] When the third clutch 6310 is in its disengaged position, with reference to Figure 32, the third clutch 6310 rotates with the drive shaft 2730 but does not transmit rotary motion to the third drive ring 6320. As can be seen from Figure 32, third clutch 6310 is separated from, or not in contact with, third drive ring 6320. As a result, rotation of drive shaft 2730 and third clutch 6310 is not transmitted to linkage drive 6330 when the third clutch assembly 6300 is in its disengaged state. When the third clutch 6310 is in its engaged position, referring to Figure 33, the third clutch 6310 is engaged with the third drive ring 6320 so that the third drive ring 6320 is expanded, or extended, radially outward. in contact with the linkage drive 6330. In at least one case, the third drive ring 6320 comprises an elastomeric band, for example. As can be seen in Figure 33, the third drive ring 6320 is pressed against an annular inner side wall 6335 of the drive screw 6330. As a result, the rotation of the drive shaft 2730 and the third clutch
[0241] [0241] As described above, the third electromagnetic actuator 6340 is configured to generate magnetic fields to move the third clutch 6310 between its disengaged (Figure 32) and engaged (Figure 33) positions. For example, with reference to Figure 32, the third electromagnetic actuator 6340 is configured to emit an EFL magnetic field that repels, or drives, the third clutch 6310 in the opposite direction to the third drive ring 6320 when the third set of 6300 clutch is in its disengaged state. The 6340 third electromagnetic actuator comprises one or more coils wound in a cavity defined in the 2530 drive shaft structure that generates the EFL magnetic field when current flows in a first direction through a third electric clutch circuit including the wound coils. The 1800 control system is configured to apply a first polarity of voltage to the third electrical clutch circuit to create current flowing in the first direction. The 1800 control system can continuously apply the first polarity of voltage to the third electrical drive shaft circuit to maintain the 6310 third clutch continuously in its disengaged position. While such an arrangement can prevent the third clutch 6310 from unintentionally engaging the third drive ring 6320, this arrangement can also consume a lot of energy. Alternatively, the control system 1800 may apply the first polarity voltage to the third electric clutch circuit for a period of time sufficient to place the third clutch 6310 in its disengaged position and then stop applying the first polarity. voltage to the third electric clutch circuit, thus resulting in lower energy consumption.
[0242] [0242] In addition to the above, the third electromagnetic actuator 6340 is configured to emit an EFD magnetic field that pulls, or drives, the third clutch 6310 toward the third drive ring 6320 when the third clutch assembly 6300 is in its engaged state. The coils of the 6340 third electromagnetic actuator generate the EFD magnetic field when current flows in a second, or opposite direction, through the third electrical clutch circuit. The 1800 control system is configured to apply opposite voltage polarity to the third electrical drive shaft circuit to create current flowing in the opposite direction. The 1800 control system can continuously apply the opposite voltage polarity to the third electrical drive shaft circuit to continuously hold the 6310 third clutch in its engaged position and maintain operational engagement between the 6320 third drive shaft and the 6320 drive. 6330 linkage. Alternatively, the 6210 third clutch can be configured to be compressed within the 6320 third drive ring when the 6210 third clutch is in its engaged position, in which case the 1800 control system may not need to continuously apply a voltage polarity to the third driveshaft electrical circuit to maintain the 6300 third clutch assembly in its engaged state. In such cases, the 1800 control system may stop applying voltage polarity once the 6310 third clutch has been sufficiently compressed into the 6320 third drive ring. In either case, the 7000 end actuator is pivotable to a first direction or in a second direction, depending on the direction in which the drive shaft 2730 is rotated, when the third clutch assembly 6300 is in its engaged state.
[0243] [0243] In addition to the above, with reference to Figures 22, 32 and 33, the articulation drive system additionally comprises a lock 6350 that prevents, or at least inhibits, articulation of the distal attachment portion 2400 of the set of drive shaft 2000 and end actuator 7000 around swivel joint 2300 when third clutch 6310 is in its disengaged position (Figure 32). Referring primarily to Figure 22, pivot link 2340 comprises a slot, or groove, 2350 defined therein wherein lock 6350 is slidably positioned in slot 2350 and extends at least partially under stationary pivot gear 2330 The lock 6350 comprises an attachment hook 6352 engaged with the third clutch 6310. More specifically, the third clutch 6310 comprises an annular slot, or groove, 6312 defined therein and the locking hook 6352 is positioned in the annular slot 6312 so that the 6350 lock is translated with the 6310 third clutch. Notably, however, the 6350 lock does not rotate, or at least substantially rotates, with the 6310 third clutch. Instead, the annular groove 6312 on the 6310 third clutch allows the 6310 to rotate. third clutch 6310 rotates with respect to lock 6350. Lock 6350 additionally comprises a locking hook 6354 slidably positioned in a slot of radially extending lock 2334 set at the bottom of stationary gear 2330. When third clutch 6310 is in its disengaged position, as illustrated in Figure 32, lock 6350 is in a locked position in which locking hook 6354 prevents end actuator 7000 from pivoting around swivel joint 2300. When third clutch 6310 is in its engaged position, as illustrated in Figure 33, lock 6350 is in an unlocked position in which locking hook 6354 is no longer positioned in locking slot 2334. Instead, locking hook 6354 is positioned in a clearance slot defined in the middle of body 2335 of stationary gear 2330. In such cases, locking hook 6354 may rotate in the slot clearance when end actuator 7000 rotates at pivot joint 2300.
[0244] [0244] In addition to the above, the radially extending locking slot 2334 shown in Figures 32 and 33 extends longitudinally, that is, along an axis that is parallel to the longitudinal axis of the axis of elongated drive 2200. After the end actuator 7000 has been pivoted, however, the locking hook 6354 is no longer aligned with the longitudinal locking slot 2334. With this in mind, the stationary gear 2330 comprises a plurality, or set, of radially extending locking slots 2334 defined in the bottom of the stationary gear 2330 so that when the third clutch 6310 is released and the lock 6350 is pulled distally after the end actuator 7000 has been pivoted, the locking hook 6354 can enter one of the locking slots 2334 and lock the end actuator 7000 in its pivoted position. Thus, as a result, the 7000 end actuator can be locked in a non-hinged and hinged position. In many cases, the 2334 locking slots can define distinct pivot positions for the 7000 end actuator. For example, the 2334 locking slots can be set at 10 degree intervals, for example, which can define orientation Distinct linkage for end actuator
[0245] [0245] Referring primarily to Figures 24 and 25, the drive shaft frame 2530 and drive shaft 2730 extend through the hinge joint 2300 into the distal attachment portion
[0246] [0246] As described above, clutches 6110, 6210 and/or 6310 can be held in their disengaged positions so that they do not unintentionally move into their engaged positions. In various arrangements, the clutch system 6000 comprises a first biasing member, such as a spring, for example, configured to bias the first clutch 6110 to its disengaged position, a second biasing member, such as a spring, for for example, configured to bias the second clutch 6210 to its disengaged position, and/or a third biasing member, such as a spring, for example, configured to bias the third clutch 6110 to its disengaged position. In these arrangements, spring bias forces can be selectively overcome by electromagnetic forces generated by electromagnetic actuators when energized by an electrical current. In addition to the above, clutches 6110, 6210 and/or 6310 may be retained in their engaged positions by drive rings 6120, 6220 and/or 6320, respectively. More specifically, in at least one case, the drive rings 6120, 6220 and/or 6320 are comprised of an elastic material that grips or frictionally holds the clutches 6110, 6210 and/or 6310, respectively, in their engaged positions. . In various alternative embodiments, the clutch system 6000 comprises a first biasing member, such as a spring, for example, configured to bias the first clutch.
[0247] [0247] While the 6000 clutch system comprises three clutches to control three actuation systems of the surgical system, a clutch system may comprise any suitable number of clutches to control any suitable number of systems. Furthermore, although the clutches of the 6000 clutch system slide proximally and distally between their engaged and disengaged positions, the clutches of a clutch system can move in any suitable manner. Furthermore, although the clutches of the 6000 clutch system are engaged one at a time to control one actuation movement at a time, several cases are envisaged in which more than one clutch may be engaged to control more than one actuation movement. at a time.
[0248] [0248] In view of the above, the reader should understand that the 1800 control system is configured to, one, operate the 1600 motor system to rotate the 2700 drive shaft system in a proper direction and, two, operate the 6000 clutch system to transfer the rotation of the 2700 drive shaft system to the proper function of the 7000 end actuator. Also, as discussed above, the 1800 control system is responsive to inputs from the 7000 end actuator. 2600 grip trigger of the 2000 drive shaft assembly and to the 1400 input system of the 1000 handle. When the 2600 grip trigger system is actuated, as discussed above, the 1800 control system activates the first set of 6100 clutch and deactivates the 6200 second clutch assembly and 6300 third clutch assembly. In these cases, the 1800 control system also supplies power to the 1600 motor system to turn the 2700 drive shaft system in a 1st direction to secure the End Actuator 7100 Jaw Assembly
[0249] [0249] When the rotation actuator 1420 is actuated in a first direction, in addition to the above, the control system 1800 activates the second clutch assembly 6200 and deactivates the first clutch assembly 6100 and the third clutch assembly 6300 In such cases, control system 1800 also supplies power to motor system 1600 to rotate drive shaft system 2700 in a first direction to rotate end actuator 7000 in a first direction. When the 1800 control system detects that the 1420 rotation actuator has been actuated in a second direction, the 1800 control system activates, or maintains activation, of the second 6200 clutch assembly and deactivates, or maintains deactivation, of the second clutch assembly 6200. first clutch assembly 6100 and third clutch assembly 6300. In these cases, the control system 1800 also supplies power to the motor system 1600 to rotate the drive shaft system 2700 in a second direction to rotate the shaft system 2700 actuator in a second direction to turn the 7000 end actuator in a second direction. When the 1800 control system detects that the 1420 rotation actuator is not actuated, the 1800 control system deactivates the second 6200 clutch assembly.
[0250] [0250] When the first linkage actuator 1432 is pressed, in addition to the above, the control system 1800 activates the third clutch assembly 6300 and deactivates the first clutch assembly 6100 and the second clutch assembly 6200. In such cases , control system 1800 also powers motor system 1600 to rotate drive shaft system 2700 in a first direction to pivot end actuator 7000 in a first direction. When the 1800 control system detects that the 1434 second linkage actuator is depressed, the 1800 control system activates, or holds the activation of the third clutch assembly 6200 and deactivates, or holds the deactivation, of the first clutch assembly 6100 and the second clutch assembly 6200. In these cases, the control system 1800 also supplies power to the motor system 1600 to rotate the drive shaft system 2700 in a second direction to pivot the end actuator 7000 in a second direction . When the 1800 control system detects that neither the 1432 linkage actuator nor the 1434 second linkage actuator is actuated, the 1800 control system deactivates the 6200 third clutch assembly.
[0251] [0251] In addition to the above, the 1800 control system is configured to change the operating mode of the stapling system based on the inputs it receives from the 2000 drive shaft assembly's 2600 grip trigger system and from the input system 1400 of the handle 1000. The control system 1800 is configured to shift the clutch system 6000 before rotating the drive shaft drive system 2700 to perform the function of the corresponding end actuator. In addition, the 1800 control system is configured to stop the drive system from rotating the 2700 drive shaft before shifting the 6000 clutch system. Such an arrangement can prevent sudden movements in the 7000 end actuator. Alternatively, the 1800 control system can shift the 600 clutch system while the 2700 drive shaft drive system is rotating. Such an arrangement can enable the 1800 control system to move quickly between operating modes.
[0252] [0252] As discussed above with reference to Figure 34, the distal attachment portion 2400 of the drive shaft assembly 2000 comprises a 6400 end actuator latch configured to prevent the 7000 end actuator from being uncoupled from unintentional mode of drive shaft assembly 2000. End actuator latch 6400 comprises a locking end 6410 selectively engageable with annular latch notched assembly 7410 defined in proximal attachment portion 7400 of end actuator 7000, one end 6420 and a pivot 6430 pivotally connecting the end actuator lock 6400 to the pivot link 2320. When the third clutch 6310 of the third clutch assembly 6300 is in its disengaged position, as illustrated in Figure 34, the third 6310 clutch contacts the 6420 proximal end of the 6400 end actuator latch so that the locking end 6410 of the 6400 end actuator latch is engaged with the 7410 locking notch assembly. In such cases, the 7000 end actuator can rotate relative to the 6400 end actuator latch but cannot translate with respect to the 6400 end actuator latch. distal attachment 2400. When the third clutch 6310 is moved to its engaged position, as illustrated in Figure 35, the third clutch 6310 is no longer engaged with the proximal end 6420 of the 6400 end actuator lock. 6400 end actuator is free to pivot upward enabling the 7000 end actuator to be separated from the 2000 drive shaft assembly.
[0253] [0253] That said, referring again to Figure 34, it is possible for the second clutch 6210 of the second clutch assembly 6200 to be in its disengaged position when the clinician separates or attempts to separate the end actuator 7000 from the drive shaft assembly 2000 As discussed above, the second clutch 6210 is engaged with the second clutch 6250 when the second clutch 6210 is in its disengaged position, and in such cases the second clutch 6250 is pushed into engagement with the link. 2340. More specifically, the second clutch lock 6250 is positioned in the channel 2345 defined in the linkage 2340 when the second clutch 6210 is engaged with the second clutch lock 6250 which can prevent, or at least prevent, the 7000 End Actuator is separated from the 2000 Drive Shaft Assembly. To facilitate the release of the 7000 End Actuator from the 2000 Drive Shaft Assembly, the control system 1800 can move the second clutch 6210 into its engaged position in addition to moving the third clutch 6310 into its engaged position. In such cases, the 7000 End Actuator may release both the 6400 End Actuator Latch and the 6250 Second Clutch Latch when the 7000 End Actuator is removed.
[0254] [0254] In at least one case, in addition to the above, the drive module 1100 comprises an input switch and/or sensor in communication with the control system 1800 through the input system 1400, and/or with the 1800 directly, which, when actuated, causes the 1800 control system to unlock the 7000 end actuator. In many cases, the 1100 drive module comprises an input screen 1440 in communication with the 1410 control system board. input 1400 which is configured to receive an unlocking action by the clinician. In response to the unlocking action, the 1800 control system can shut down the 1600 engine system, if it is running, and unlock the 7000 end actuator as described above. The input screen 1440 is also configured to receive a clinician lockout action whereby the input system 1800 moves the second clutch assembly 6200 and/or third clutch assembly 6300 to their non-actuated states to lock. the 7000 end actuator to the 2000 drive shaft assembly.
[0255] [0255] Figure 37 shows a drive shaft assembly 2000' according to at least one alternative embodiment. The 2000' drive shaft assembly is similar to the 2000 drive shaft assembly in many respects, most of which are not discussed here for the sake of brevity. Similar to the drive shaft assembly 2000, the drive shaft assembly 2000' comprises a drive shaft frame, i.e., the drive shaft frame 2530'. The drive shaft structure 2530' comprises a longitudinal passage 2535' and, in addition, a plurality of clutch position sensors, i.e. a first sensor
[0256] [0256] The second sensor 6280' is in signal communication with the control system 1800 as part of a second detection circuit. The second detection circuit comprises signal wires extending through the longitudinal passage 2535'; however, the second detection circuit may comprise a wireless signal transmitter and receiver for bringing the second sensor 6280' into signal communication with the control system 1800. The second sensor 6280' is positioned and arranged to detect the signal. position of the second clutch 6210 of the first clutch assembly 6200. Based on data received from the second sensor 6280', the control system 1800 can determine whether the second clutch 6210 is in its engaged position, in its disengaged position, or somewhere between them. With this information, the 1800 control system can assess whether or not the 6210 second clutch is in the correct position, given the operating status of the surgical instrument. For example, if the surgical instrument is in its end actuator rotation operating state, the 1800 control system can verify that the 6210 second clutch is properly positioned in its engaged position. In such cases, the control system 1800 can also verify that the first clutch 6110 is in its disengaged position via the first sensor 6180' and, in addition to the above, the control system 1800 can also verify that the third clutch 6310 is in its disengaged position via the third sensor 6380'. Correspondingly, the 1800 control system can verify that the 6110 second clutch is properly positioned in its disengaged position if the surgical instrument is not in its end actuator rotation state. When the 6210 second clutch is not in its proper position, the 1800 control system may actuate the 6240 second electromagnetic actuator in an attempt to properly position the 6210 second clutch. Similarly, the 1800 control system may actuate the 6140 and/or 6340 electromagnetic actuators to properly position the 6110 and/or 6310 clutches, if necessary.
[0257] [0257] The third sensor 6380' is in signal communication with the control system 1800 as part of a third detection circuit. The third detection circuit comprises signal wires extending through the longitudinal passage 2535'; however, the third detection circuit may comprise a wireless signal transmitter and receiver to place the third sensor 6380' in signal communication with the control system 1800. The third sensor 6380' is positioned and arranged to sense the position of the third clutch 6310 of the third clutch assembly 6300. Based on data received from the third sensor 6380', the control system 1800 can determine whether the third clutch 6310 is in its engaged position, in their disengaged position or somewhere in between. With this information, the 1800 control system can assess whether or not the 6310 third clutch is in the correct position, given the operating state of the surgical instrument. For example, if the surgical instrument is in its end actuator linkage operating state, the 1800 control system can verify that the 6310 third clutch is properly positioned in its engaged position. In such cases, the control system 1800 can also verify that the first clutch 6110 is in its disengaged position via the first sensor 6180' and that the second clutch 6210 is in its disengaged position via the second sensor 6280'. Correspondingly, the 1800 control system can verify that the 6310 third clutch is properly positioned in its disengaged position if the surgical instrument is not in its end actuator pivot state. When the 6310 third clutch is not in its proper position, the 1800 control system may actuate the 6340 third electromagnetic actuator in an attempt to properly position the 6310 second clutch. Similarly, the 1800 control system can drive the 6140 and/or 6240 electromagnetic actuators to properly position the 6110 and/or 6210 clutches, if necessary.
[0258] [0258] In addition to the above, clutch position sensors i.e. first sensor 6180', second sensor 6280' and third sensor 6380' may comprise any suitable type of sensor. In various cases, the first sensor 6180', the second sensor 6280' and the third sensor 6380' each comprise a proximity sensor. In this arrangement, sensors 6180', 6280', and 6380' are configured to detect whether or not clutches 6110, 6210, and 6310, respectively, are in their engaged positions. In various cases, the first sensor 6180', the second sensor 6280' and the third sensor 6380' each comprise a Hall effect sensor, for example. In such an arrangement, sensors 6180', 6280', and 6380' can not only detect whether or not clutches 6110, 6210, and 6310, respectively, are in their engaged positions, but sensors 6180', 6280' and 6380' can also detect how close the jaws 6110, 6210 and 6310 are relative to their engaged or disengaged positions.
[0259] [0259] Figure 38 shows a 2000' drive shaft assembly and a 7000' end actuator, according to at least one alternative modality. The 7000” End Actuator is similar to the 7000 End Actuator in many respects, most of which will not be discussed here for the sake of brevity. Similar to the 7000 end actuator, the 7000” drive shaft assembly comprises a 7100 jaw assembly and a jaw assembly drive configured to move the 7100 jaw assembly between its open and closed configurations. The jaw assembly drive comprises 7140 drive links, a 7150” drive nut and a 6130” drive bolt. The 7150” drive nut comprises a 7190” sensor positioned thereon that is configured to detect the position of a 6190” magnetic element positioned on the 6130” drive screw. The magnetic element 6190” is positioned in an elongated opening 6134” defined in the drive screw 6130” and may comprise a permanent magnet and/or may be comprised of iron, nickel and/or any suitable metal, for example. In several cases, the 7190” sensor comprises a proximity sensor, for example, which is in signal communication with the 1800 control system. In certain cases, the 7190” sensor comprises a Hall effect sensor, for example, in signal communication with the 1800 control system. In certain cases, the 7190” sensor comprises an optical sensor, for example, and the 6190” detectable element, comprises an optically detectable element, such as a reflective element, for example. . In either case, the 7190” sensor is configured to communicate wirelessly with the 1800 control system through a wireless signal transmitter and receiver and/or through a wired connection that extends through the frame passage. drive shaft 2532', for example.
[0260] [0260] The 7190" sensor, in addition to the above, is configured to detect when the 6190" magnetic element is in a position adjacent to the 7190" sensor so that the 1800 control system can use this data to determine that the set gripper 7100 has reached the end of its gripping stroke. At this point, the control system
[0261] [0261] Figure 39 shows a 2000'" drive shaft assembly and a 7000'" end actuator, according to at least one alternative embodiment. The 2000’’ drive shaft assembly is similar to the 2000 and 2000’ drive shaft assemblies in many respects, most of which are not discussed here for the sake of brevity. The 7000''' End Actuator is similar to the 7000 and 7000" End Actuators in many respects, most of which will not be discussed here for the sake of brevity. Similar to the 7000 End Actuator, the 7000'” End Actuator comprises a 7100 jaw assembly and a jaw assembly drive configured to move the 7100 jaw assembly between its open and closed configurations and, in addition, a of end actuator rotation which rotates the end actuator 7000”' with respect to the distal attachment portion 2400 of the drive shaft assembly 2000'. The end actuator rotation drive comprises a 6230'” outer housing which is rotated relative to a 7000'” end actuator drive shaft frame 2530'” by the 6200 second clutch assembly. drive 2530'” comprises a sensor 6290'” positioned therein which is configured to detect the position of a magnetic element 6190'” positioned in and/or on the outer cabinet 6230'''. Magnetic element 6190'" may comprise a permanent magnet and/or may be comprised of iron, nickel and/or any suitable metal, for example.
[0262] [0262] Figure 40 shows a drive shaft assembly 2000'''', according to at least one embodiment. The 2000'''' Drive Shaft Assembly is similar to the 2000, 2000' and 2000'' Drive Shaft Assemblies in many respects, most of which will not be repeated here for the sake of brevity. Similar to drive shaft assembly 2000, drive shaft assembly 2000'''' comprises, among other things, an elongate drive shaft 2200, a pivot joint 2300, and a distal attachment portion 2400 configured to receive an end actuator such as the 7000' end actuator for example. Similar to the drive shaft assembly 2000, the drive shaft assembly 2000'''' comprises a pivot drive, i.e., a pivot drive 6330'''' configured to rotate the distal attachment portion 2400 and the end actuator 7000' at the pivot joint 2300. Similar to the above, a drive shaft structure 2530''' comprises a sensor positioned therein to detect the position, and/or rotation, of an element magnet 6390'''' positioned on and/or on articulation drive 6330''''. The magnetic element 6390'''' may comprise a permanent magnet and/or may be comprised of iron, nickel and/or any suitable metal, for example. In several cases, the sensor comprises a proximity sensor, for example, in signal communication with the 1800 control system. In certain cases, the sensor comprises a Hall effect sensor, for example, in signal communication with the 1800 control system. 1800 control. In either case, the sensor is configured to communicate wirelessly with the 1800 control system via a wireless signal transmitter and receiver and/or via a wired connection that extends across the 2532' axle frame passage, for example. In various cases, the control system 1800 may use the sensor to confirm that the magnetic element 6390'''' is rotating and thereby confirm that the third clutch assembly 6300 is in its actuated state. Similarly, the control system 1800 can use the sensor to confirm that the magnetic element 6390'''' is not rotating and thereby confirm that the third clutch assembly 6300 is in its non-actuated state. In certain cases, the 1800 control system may also use the sensor to confirm that the third clutch assembly 6300 is in its non-actuated state by confirming that the third clutch 6310 is adjacent to the sensor.
[0263] [0263] Referring again to Figure 40, the 2000'''' drive shaft assembly comprises a 6400' end actuator lock configured to releasably lock the 7000' end actuator, for example to the drive shaft assembly 2000''''. The 6400' End Actuator Latch is similar to the 6400 End Actuator Latch in many respects, most of which will not be discussed here for the sake of brevity. Notably, however, a proximal end 6420' of latch 6400' comprises a tooth 6422' configured to engage annular slot 6312 of third clutch 6310 and releasably hold third clutch 6310 in its disengaged position. . That said, actuation of the third electromagnetic assembly 6340 can disengage the third clutch 6310 from the 6400' end actuator latch. Also, in these cases, proximal movement of the 6310 third clutch to its engaged position rotates the 6400' end actuator lock to a locked position and in engagement with the 7410 lock notches to lock the 7000 end actuator. ' to drive shaft assembly 2000''''. Correspondingly, distal movement of third clutch 6310 to its disengaged position unlocks end actuator 7000' and enables end actuator 7000' to be disassembled from drive shaft assembly 2000''''.
[0264] [0264] In addition to the above, an instrument system that includes a handle and a drive shaft assembly attached thereto can be configured to perform a diagnostic check to assess the condition of the 6100, 6200, and 6300 clutch assemblies. In at least one case, the 1800 control system sequentially actuates the 6140, 6240, and/or 6340 electromagnetic actuators - in any suitable order - to verify the positions of the 6110, 6210, and/or 6310 clutches, respectively, and/or to verify that clutches are responsive to electromagnetic actuators and thus are not blocked. The 1800 control system may use sensors, including any of the sensors disclosed herein, to check the movement of the 6110, 6120, and 6130 clutches in response to electromagnetic fields created by the 6140, 6240, and/or 6340 electromagnetic actuators. In addition, the diagnostic check may also include checking the movements of the drive systems. In at least one case, the 1800 control system sequentially actuates the 6140, 6240 and/or 6340 electromagnetic actuators - in any suitable order - to verify that the jaw drive opens and/or closes the 7100 jaw assembly, the Rotation drive rotates the end actuator 7000, and/or the linkage drive pivots the end actuator 7000, for example. The 1800 control system can use sensors to check the movements of the 7100 gripper assembly and the 7000 end actuator.
[0265] [0265] The 1800 control system can run the diagnostic test at any suitable time, such as when a drive shaft assembly is attached to the handle and/or when the handle is activated, for example.
[0266] [0266] Figures 41 to 43 show a 6000' clutch system according to at least one alternative embodiment. The 6000' clutch system is similar to the 6000 clutch system in many respects, most of which will not be repeated here for brevity. Similar to the 6000 clutch system, the 6000' clutch system comprises a 6100' clutch assembly that is operable to selectively couple a 6030' swivel drive input with a 6130' swivel drive output. The 6100' clutch assembly comprises 6110' clutch plates and 6120' drive rings. Clutch plates 6110' are comprised of a magnetic material, such as iron and/or nickel, for example, and may comprise a permanent magnet. As described in more detail below, clutch plates 6110' are movable between non-actuated positions (Figure 42) and actuated positions (Figure 43) within actuation output 6130'. Clutch plates 6110' are slidably positioned in defined openings in drive output 6130' so that clutch plates 6110' rotate drive output 6130' regardless of whether clutch plates 6110' are in their positions. not actuated or actuated.
[0267] [0267] When the 6110' clutch plates are in their non-actuated positions, as illustrated in Figure 42, the rotation of the 6030' drive input is not transferred to the 6130' drive output. More specifically, when drive input 6030' is rotated, in such cases drive input 6030' slides through and rotates with respect to drive rings 6120' and as a result drive rings 6120' do not drive. clutch plates 6110' and drive output 6130'. When clutch plates 6110' are in their actuated positions, as illustrated in Figure 43, clutch plates 6110' resiliently compress drive rings 6120' against drive input 6030'. The drive rings 6120' are comprised of any suitable compressible material, such as rubber for example.
[0268] [0268] Figure 44 shows an end actuator 7000a that includes a jaw assembly 7100a, a jaw assembly drive, and a clutch system 6000a, in at least one alternative embodiment. The jaw assembly 7100a comprises a first jaw 7110a and a second jaw 7120a that are selectively rotatable about a pivot 7130a. The clutch assembly drive comprises a translatable actuator rod 7160a and drive links 7140a that are pivotally coupled to the actuator stem 7160a by a pivot 7150a. Drive links 7140a are also pivotally coupled to jaws 7110a and 7120a so that jaws 7110a and 7120a are rotated closed when actuator stem 7160a is pulled proximally and rotated open when actuator stem 7160a is pushed distally. The 6000a clutch system is similar to the 6000 and 6000' clutch systems in many respects, most of which will not be repeated here for the sake of brevity. The clutch system 6000a comprises a first clutch assembly 6100a and a second clutch assembly 6200a which are configured to selectively transmit the rotation of a drive input 6030a to rotate the jaw assembly 7100a about a geometric axis. longitudinally and pivot the jaw assembly 7100a around a articulation joint 7300a, respectively, as described in more detail below.
[0269] [0269] The first clutch assembly 6100a comprises clutch plates 6110a and drive rings 6120a and functions similarly to the clutch plates 6110' and drive rings 6120' discussed above. When the 6110a clutch plates are actuated by a 6140a electromagnetic actuator, the rotation of the 6030a drive input is transferred to an external 7200a drive shaft housing. More specifically, the 7200a outer drive shaft housing comprises a 7210a proximal outer housing and a 7220a distal outer housing that is pivotally supported by the 7210a proximal outer housing and rotated relative to the 7210a proximal outer housing by the 6030a drive port when the 6110a clutch plates are in their actuated position. Rotation of the distal outer housing 7220a rotates the jaw assembly 7100a about the longitudinal axis due to the fact that the pivot 7130a of the jaw assembly 7100a is mounted to the distal outer casing 7220a. As a result, external drive shaft housing 7200a rotates jaw assembly 7100a in a first direction when external drive shaft housing 7200a is rotated in a first direction by drive input 6030a. Similarly, external drive shaft housing 7200a rotates jaw assembly 7100a in a second direction when external drive shaft housing 7200a is rotated in a second direction by drive input 6030a. When the electromagnetic actuator 6140a is de-energized, the drive rings 6120a expand and the clutch plates 6110a are moved to their non-actuated positions, thus decoupling the end actuator rotation drive from the drive input 6030a.
[0270] [0270] The second clutch assembly 6200a comprises clutch plates 6210a and drive rings 6220a and functions similarly to the clutch plates 6110' and drive rings 6120' discussed above. When clutch plates 6210a are actuated by an electromagnetic actuator 6240a, rotation of drive input 6030a is transferred to linkage drive 6230a. The pivot drive 6230a is pivotally supported within an external drive shaft housing 7410a of an end actuator attachment portion 7400a and is pivotally supported by a drive shaft frame 6050a that extends through the drive shaft housing external 7410a. The pivot drive 6230a comprises a gear face defined therein that is operatively interleaved with a stationary gear face 7230a defined in the proximal outer housing 7210a of the outer drive shaft housing 7200a. As a result, the articulation drive 6230a pivots the external drive shaft housing 7200a and the jaw assembly 7100a in a first direction when the articulation drive 6230a is rotated in a first direction by the drive input 6030a. Similarly, the articulation drive 6230a pivots the external drive shaft housing 7200a and the jaw assembly 7100a in a second direction when the articulation drive 6230a is rotated in a second direction by the drive input 6030a. When the 6240a electromagnetic actuator is de-energized, the 6220a drive rings expand and the 6210a clutch plates are moved to their non-actuated positions, thus decoupling the linkage drive from the 6030a drive input.
[0271] [0271] In addition to the above, a drive shaft assembly 4000 is illustrated in Figures 45 to 49. The drive shaft assembly 4000 is similar to the drive shaft assemblies 2000, 2000', 2000''' and 2000' ''' in many respects, most of which will not be repeated here for the sake of brevity. The drive shaft assembly
[0272] [0272] As discussed above, with reference primarily to Figures 47-49, the frame 4500 of the drive shaft assembly 4000 comprises a frame drive shaft 4510. The frame drive shaft 4510 comprises a notch, or cutout, 4530 defined in the same. As discussed in more detail below, the cutout 4530 is configured to provide clearance for a jaw closure actuation system 4600. The frame 4500 additionally comprises a distal portion 4550 and a bridge 4540 that connects the 4550 to the drive shaft of the frame 4510. The frame 4500 further comprises a longitudinal portion 4560 that extends through the elongate drive shaft 4200 to the distal attachment portion 2400. Similar to the above, the drive shaft of the frame 4510 comprises one or more electrical paths defined in and/or within it. Electrical tracks extend through longitudinal portion 4560, distal portion 4550, bridge 4540, and/or any suitable portion of frame drive shaft 4510 to electrical contacts 2520. Referring primarily to Figure 48, the distal portion 4550 and longitudinal portion 4560 comprise a longitudinal opening defined therein which is configured to receive a rod 4660 of the jaw closure actuation system 4600, as described in more detail below.
[0273] [0273] As also discussed above, with reference primarily to Figures 48 and 49, the drive system 4700 of the drive shaft assembly 4000 comprises a drive shaft 4710. The drive shaft 4710 is pivotally supported within the housing of the proximal drive shaft 4110 by the frame drive shaft 4510 and is rotatable about a longitudinal axis that extends through the frame drive shaft. The 4700 drive system additionally comprises a 4750 transfer drive shaft and a 4780 output drive shaft. The 4750 transfer drive shaft is also pivotally supported within the proximal drive shaft housing 4110 and is rotatable in around a longitudinal axis that extends parallel to, or at least substantially parallel to, the drive axis of the structure
[0274] [0274] In addition to the above, with reference primarily to Figures 47 and 48, the 4600 Jaw Closing Actuation System comprises an actuation, or shears, trigger 4610 rotatably coupled to the proximal drive shaft housing. 4110 about a pivot 4620. Actuation trigger 4610 comprises an elongate portion 4612, a proximal end 4614, and a jaw ring opening 4616 defined at the proximal end 4614 that is configured to be wielded by the clinician. Drive shaft assembly 4000 further comprises a stationary jaw 4160 extending from proximal housing 4110. Stationary jaw 4160 comprises an elongated portion 4162, a proximal end 4164, and a jaw ring opening 4166 defined at the 4164 proximal end which is configured to be held by the physician. In use, as described in more detail below, the actuation trigger 4610 is rotatable between a non-actuated position and an actuated position (Figure 48), i.e. toward the stationary jaw 4160, to close the actuator jaw assembly 8100 end 8000.
[0275] [0275] Referring primarily to Figure 48, the 4600 jaw closing actuation system additionally comprises a 4640 drive linkage pivotally coupled to the proximal drive shaft housing 4110 around a pivot 4650 and, in addition, an actuation rod 4660 operatively coupled to actuation linkage 4640. Actuation rod 4660 extends through an opening defined in the longitudinal frame portion 4560 and is translatable along the longitudinal axis of the shaft structure. drive 4500. Actuation rod 4660 comprises a distal end operatively coupled to gripper assembly 8100 and a proximal end 4665 positioned in a drive slot 4645 defined in drive link 4640 such that actuation rod 4660 is translated longitudinally. when drive link 4640 is rotated about pivot 4650. Notably, proximal end 4665 is rotatably supported inside the 4645 drive slot so that the 4660 actuation rod can rotate with the 8000 end actuator.
[0276] [0276] In addition to the above, the actuation trigger 4610 additionally comprises an actuation arm 4615 configured to engage and rotate the actuation link 4640 proximally, and translate the actuation rod 4660 proximally, when the actuation trigger - action 4610 is actuated, i.e. moved closer to the proximal drive shaft housing 4110. In such cases, proximal rotation of the drive link 4640 resiliently compresses a biasing member, such as a coil spring 4670, by For example, positioned between the 4640 drive link and the 4510 frame drive shaft. When the 4610 actuation trigger is released, the 4670 compressed coil spring re-expands and pushes the 4640 drive link and the 4660 actuation rod distally to open the 8000 end actuator jaw assembly 8100. In addition, distal rotation of the 4640 actuation link drives, and automatically rotates, the 4610 actuation trigger back to its unactuated position. That said, the clinician can manually return the 4610 actuation trigger to its unactuated position. In such cases, the 4610 actuation trigger could be opened slowly. In either case, the drive shaft assembly 4000 additionally comprises a latch configured to releasably hold the actuation trigger 4610 in its actuated position so that the clinician can use his or her hand to perform another task without the unintentional opening of the 8100 jaw assembly.
[0277] [0277] In several alternative embodiments, in addition to the above, the 4660 actuation rod can be pushed distally to close the 8100 grip assembly. In at least one of these cases, the 4660 actuation rod is mounted directly on the trigger. actuation trigger 4610 so that when actuation trigger 4610 is actuated, actuation trigger 4610 actuates actuation rod 4660 distally. Similar to the above, actuation trigger 4610 can compress a spring when actuation trigger 4610 is closed so that when actuation trigger 4610 is released, actuation rod 4660 is pushed proximally.
[0278] [0278] In addition to the above, the 4000 drive shaft assembly has three functions - opening/closing the jaw assembly of an end actuator, rotation of the end actuator around a longitudinal geometric axis, and pivoting of the end actuator. end around a geometric axis of articulation. The rotation and linkage functions of the 4000 end actuator are activated by the 1600 motor assembly and the 1800 control system of the 1100 drive module while the jaw actuation function is manually actuated by the closing actuation system. 4600 gripper. The 4600 gripper closing actuation system could have been a motor driven system but instead the 4600 gripper closing actuation system was kept as a manually operated system so that a clinician might have a better feel of the fabric being stapled inside the end actuator. While the motorization of the end actuator rotation and actuation systems provides certain advantages for controlling the position of the end actuator, the motorization of the 4600 jaw closing actuation system can cause the clinician to lose a tactile sense of the applied force. to the tissue and may not be able to judge whether the force is insufficient or excessive. In this way, the 4600 gripper closing actuation system is manually actuated even though the end actuator pivot and rotation systems are motor driven.
[0279] [0279] Figure 50 is a logic diagram of the 1800 control system of the surgical system shown in Figure 1, according to at least one embodiment. The 1800 control system comprises a control circuit. The control circuit includes a microcontroller
[0280] [0280] The 1840 microcontroller can be any single-core or multi-core processor, such as those known under the tradename ARM Cortex available from Texas Instruments, for example. In at least one respect, the 1840 microcontroller is a Cortex-M4F LM4F230H5QR ARM processor core, available from Texas Instruments, for example, that comprises an integrated 256 KB single-cycle flash memory, or other memory. non-volatile, up to 40 MHz, a prefetch buffer to optimize performance above 40 MHz, a 32 KB single-cycle serial random access memory (SRAM), a loaded internal read-only memory (ROM) with StellarisWare® software, 2 KB electrically erasable programmable read-only memory (EEPROM), one or more pulse width modulation (PWM) modules and/or frequency modulation (FM) modules ), one or more analog quadrature encoder (QEI) inputs, one or more 12-bit analog-to-digital converters (ADC) with 12 analog input channels, details of which are available in the product data sheet .
[0281] [0281] In many cases, the 1840 microcontroller comprises a safety controller comprising two controller-based families, such as the TMS570 and RM4x known under the trade name Hercules ARM Cortex R4, also available from Texas Instruments. The safety controller can be configured specifically for safety critical applications IEC 61508 and ISO 26262, among others, to provide advanced built-in safety features while providing scalable performance, connectivity and memory options.
[0282] [0282] The 1840 microcontroller is programmed to perform various functions, such as precisely controlling the speed and/or position of the 7150 drive nut of the jaw closure assembly, for example. The 1840 microcontroller is also programmed to precisely control the rotational speed and position of the 7000 end actuator and the speed and pivot position of the 7000 end actuator. In many cases, the 1840 microcontroller computes a response in the 1840 microcontroller software. The computed response is compared to a measured response from the real system to obtain an "observed" response, which is used for actual decisions based on feedback. The observed response is a favorable and adjusted value that balances the uniform and continuous nature of the simulated response with the measured response, which can detect external influences on the system.
[0283] [0283] The 1610 motor is controlled by an 1850 motor drive. In various forms, the 1610 motor can be a brushed direct current drive motor, with a maximum rotational speed of approximately 25,000 RPM, for example. In other arrangements, the motor may include a brushless motor, a wireless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. Motor driver 1850 may comprise an H-bridge driver comprising field effect transistors (FETs), for example. The 1850 motor driver can be an A3941, available from Allegro Microsystems, Inc. The A3941 1850 driver is a full-bridge controller for use with metal oxide semiconductor field effect transistors (MOSFETs). N-channel external power transistors), specifically designed for inductive loads such as brushed direct current motors. In many cases, the 1850 driver comprises a unique charge pump regulator that provides full port actuation (>10V) for battery voltages up to 7V and enables the A3941 to operate with reduced port actuation, up to 5 .5 V. A bootstrap capacitor can be used to supply the voltage in excess of that supplied by the battery needed for N-channel MOSFETs. An internal charge pump for the upside drive allows direct current operation (100% duty cycle). The full bridge can be driven in fast or slow decay modes using diodes or synchronous rectification. In slow fall mode, current recirculation can take place via FET from either the upside or the downside. Power FETs are "shoot-through" protected by a resistor-adjustable idle time. Built-in diagnostics provide indication of undervoltage, overtemperature and power bridge faults and can be configured to protect power MOSFETs under most short circuit conditions. Other motor starters can be readily replaced.
[0284] [0284] The 1860 tracking system comprises a controlled motor drive circuit arrangement comprising one or more position sensors, such as the 1880, 1890, 6180', 6280', 6380', 7190'' and/or 6290 sensors. ''', for example. Position sensors for an absolute positioning system provide a unique position signal that corresponds to the location of a displacement member. As used herein, the term displacement member is used generically to refer to any movable member of the surgical system. In various other cases, the displacement member may be coupled to any position sensor 472 suitable for measuring linear displacement. Linear displacement sensors can include contact or non-contact displacement sensors. Linear displacement sensors may comprise variable differential linear transformers (LVDT), variable reluctance differential transducers (DVRT), a sliding potentiometer, a magnetic detection system comprising a moving magnet and a series of linearly arranged Hall effect sensors. , a magnetic detection system comprising a fixed magnet and a series of movable, linearly arranged Hall effect sensors, an optical detection system comprising a moving light source and a series of linearly arranged photodiodes or photodetectors, or a optical detection comprising a fixed light source and a series of linearly arranged mobile photodiodes or photodetectors, or any combination thereof.
[0285] [0285] Position sensors 1880, 1890, 6180', 6280', 6380', 7190”, and/or 6290''', for example, can comprise any number of magnetic detection elements, such as sensors magnets classified according to their measurement of the total magnetic field or the vector components of the magnetic field. The techniques used to produce both types of magnetic sensors cover many aspects of physics and electronics. Technologies used for magnetic field detection include explorer coil, flowmeter, optically pumped, nuclear precession, SQUID, Hall effect, anisotropic magnetoresistance, giant magnetoresistance, magnetic tunnel junctions, giant magnetoimpedance, magnetostrictive composites. /piezoelectric, magnetodiode, magneto-transistor, optical fiber, magneto-optic and magnetic sensors based on microelectromechanical systems, among others.
[0286] [0286] In many cases, one or more position sensors of the 1860 tracking system comprise a rotating magnetic absolute positioning system. Such position sensors can be implemented as an AS5055EQFT single circuit magnetic rotary position sensor available from Austria Microsystems, AG and can be interfaced with the 1840 controller to provide an absolute positioning system. In certain cases, a 472 position sensor is a low voltage, low power component and includes four Hall effect elements in an area of the position sensor that is situated adjacent to a magnet. An A-D converter and an intelligent power management controller are also provided on the integrated circuit. A CORDIC processor ("Coordinate Rotation Digital Computer", also known as digit-by-digit method and Volder algorithm, is provided to implement a simple and efficient algorithm for computing hyperbolic and trigonometric functions that require only addition, subtraction, bit shift, and table lookup operations. Angular position, alarm bits, and magnetic field information are transmitted through a standard serial communication interface, such as an SPI interface. for the 1840 controller. Position sensors can provide 12 or 14 bits of resolution, for example. The position sensors can be an AS5055 integrated circuit supplied in a small 16-pin QFN package whose measurement corresponds to 4 x 4 x 0.85 mm, for example.
[0287] [0287] The 1860 tracking system may comprise and/or be programmed to implement a feedback controller, such as a PID, status feedback, and adaptive controller. A power supply converts the feedback controller signal into a physical input to the system, in this case voltage. Other examples include pulse width modulation (PWM) and/or frequency modulation (FM) of voltage, current and power. Other sensor(s) may be provided to measure physical parameters of the physical system in addition to position. In various cases, the other sensor(s) may include sensor arrangements as described in US Patent No. 9,345,481 entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which is incorporated herein by reference in its entirety. totality; US Patent Application Publication No. 2014/0263552 entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which is incorporated herein by reference in its entirety; and US Patent Application No. 15/628,175, entitled TECHNIQUES FOR ADAPTIVE CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING INSTRUMENT, which is incorporated herein by reference in its entirety. In a digital signal processing system, an absolute positioning system is coupled to a digital data capture system where the output of the absolute positioning system will have a finite resolution and sampling frequency. The absolute positioning system may comprise a matching and matching circuit for matching a computed response with a measured response using algorithms such as a weighted average and a theoretical control circuit which directs the computed response to the measured response. The computed response of the physical system considers properties such as mass, inertia, viscous friction, resistance to inductance, etc., to predict what the states and outputs of the physical system will be, given the input.
[0288] [0288] The absolute positioning system provides an absolute position of the displacement member by energizing the instrument without retracting or advancing the displacement member to a reset (zero or home) position, as may be required with Conventional rotary encoders that merely count the number of forward or reverse steps the 1610 motor has taken to infer the position of a device actuator, drive bar, knife, or the like.
[0289] [0289] A 1880 sensor comprising a strain gauge or micro strain gauge, for example, is configured to measure one or more end actuator parameters, such as, for example, the strain experienced by the 7110 and 7120 grips during a pull-out operation. pre-ension. The measured effort is converted to a digital signal and fed to the 1820 processor. In addition to or instead of the 1880 sensor, an 1890 sensor comprising a Load sensor, for example, can measure the Closing Force applied by the actuation system. 7110 and 7120 closure for grips. In many cases, an 1870 current sensor can be used to measure the current drawn by the 1610 motor. The force required to hold the 7100 jaw assembly may correspond to the current drawn by the 1610 motor, for example. The measured force is converted into a digital signal and fed to the 1820 processor. A magnetic field sensor can be used to measure the thickness of captured tissue. The magnetic field sensor measurement can also be converted to a digital signal and fed to the 1820 processor.
[0290] [0290] Measurements of tissue compression, tissue thickness, and/or the force required to close the end actuator on the tissue as measured by the sensors can be used by the 1840 controller to characterize position and/or velocity of the mobile member being tracked. In at least one case, a memory 1830 may store a technique, an equation, and/or a lookup table that may be used by the microcontroller 1840 in evaluation. In many cases, the 1840 controller can provide the surgical instrument user with a choice as to the manner in which the surgical instrument is to be operated. For this purpose the 1440 display can show a variety of instrument operating conditions and can include touch screen functionality for data entry. In addition, the information displayed on the 1440 screen can be overlaid with images captured through the imaging modules of one or more endoscopes and/or one or more additional surgical instruments used during the surgical procedure.
[0291] [0291] As discussed above, the drive module 1100 of the handle 1000 and/or the drive shaft assemblies 2000, 3000, 4000, and/or 5000, for example, attachable thereto comprise control systems. Each of the control systems may comprise a circuit board that has one or more processors and/or memory devices. Among other things, control systems are configured to store sensor data, for example. They are also configured to store data that identifies the drive shaft assembly for grip 1000. In addition, they are also configured to store data that includes whether or not the drive shaft assembly has previously been used and/or how many times the drive shaft assembly has been used. This information can be obtained by the handle 1000 to assess whether or not the drive shaft assembly is suitable for use and/or has been used less than a predetermined number of times, for example.
[0292] [0292] In addition to the above, the first module connector 1120 of the drive module 1100 comprises a battery side port defined on the side of the drive module 1100. Similarly, the second module connector 1120' comprises a port battery set at the proximal end of the drive module
[0293] [0293] Referring primarily to Figures 55 and 56, the connector 1220 comprises two latches 1240 extending therefrom. Latches 1240 are positioned on opposite sides of connector 1220 so that they comprise opposing latch pads that releasably secure power module 1200 to power module 1100. Battery side door 1120 comprises door openings. latch 1125 defined in cabinet 1100 that are configured to receive latches 1240 of power module 1200 and similarly, proximal battery door 1120' comprises latch openings 1125' defined in cabinet 1100 which are also configured to receive the 1240 latches on the 1200 power module. Although the 1125 latch openings on the 1120 side battery door and the 1125' latch openings on the 1120' proximal battery door limit the orientations in which the 1200 power module can be mounted. - fitted to each battery port 1120 and 1120', i.e. two orientations for each battery port, the power module is however operablely attachable to both battery ports 1120 and 1120'.
[0294] [0294] In addition to the above, the latches 1240 of the power module 1200 are configured to engage the drive module 1100 in a snap-fit manner. In many cases, the latches 1240 resiliently flex radially outward when the power module 1200 is mounted to the drive module 1100 and then resiliently move, or snap-fit, radially inward when the power module is 1200 is fully seated within one of the doors 1120 and 1120' to lock the power module 1200 to the drive module 1100. In various cases, the locks 1240 comprise flexible arms that deflect radially in and out as described above. while, in some cases, the latches 1240 comprise one or more biasing elements, such as Springs, for example, configured to resiliently push the latches 1240 into their internal or locked positions. In various embodiments, power module 1200 may comprise members that are press fit into openings defined in ports 1120 and 1120' to retain power module 1200 in the drive module.
[0295] [0295] In addition to the above, the electrical contacts of the 1200 power module are set on the top, or face, of the connector
[0296] [0296] In addition to the above, the power module 1300 is operably attachable to the drive module 1100 at the proximal battery port 1120', as shown in Figures 59 to 66, but not at the battery side port 1120, as illustrated. in Figures 69 and 70. This is because the 1320 connector of the 1300 power module is compatible with the proximal portion of the 1120' battery, but not the side battery port.
[0297] [0297] In addition to the above, other circumstances may prevent a power module from being attached to one of the battery ports 1120 and 1120'. For example, one of the battery ports may have an asymmetric geometry that is configured to receive a complementary geometry from only one of the power modules.
[0298] [0298] Power modules 1200 and 1300 are configured to supply power to drive module 1100 at the same, or at least substantially the same, voltage. For example, each power module 1200 and 1300 is configured to supply power to the drive module 1100 at 3V direct current (DC), for example. The control system 1800 of the drive module 1100 comprises one or more power inverters, for example, configured to convert direct current (DC) to alternating current (AC) to the extent that alternating current (AC) is required. That said, the power modules 1200 and 1300 can be configured to supply power to the drive module 1100 at any suitable voltage. In at least one case, the 1200 and/or 1300 power modules are configured to supply AC power to the drive module. In at least one of these cases, the power modules 1200 and/or 1300 each comprise one or more power inverters. In alternative embodiments, the 1200 and 1300 power modules are configured to supply power to the 1100 drive module at different voltages. In such embodiments, the configurations of ports 1120 and 1120' discussed above may prevent a power module having a higher voltage from being attached to a lower voltage port. Likewise, the configurations of ports 1120 and 1120' can prevent a power module that has a lower voltage from being attached to a higher voltage port, if desired.
[0299] [0299] In many cases, the 1200 and 1300 power modules are configured to supply the same, or at least substantially the same, current to the drive module. In at least one case, power modules 1200 and 1300 supply the same, or at least substantially the same, magnitude of current to drive module 1100. In alternative embodiments, power modules 1200 and 1300 are configured to supply different currents to the drive module 1100. In at least one case, the power module 1200 supplies a current to the drive module 1100 that has a magnitude that is twice the current supplied by the power module 1300, for example. In at least one of these cases, the battery cells of the power module 1200 are arranged in parallel to supply the same voltage as the power module 1300 but at twice the current. Similar to the above, the configurations of ports 1120 and 1120' discussed above can prevent a power module that has a higher current from being attached to a lower current port. Likewise, the 1120 and 1120' port configurations can prevent a power module that has a lower current from being attached to a higher current port, if desired.
[0300] [0300] In addition to the above, the 1800 control system is configured to adaptively manage the power supplied by the 1200 and 1300 power modules. In many cases, the 1800 control system comprises one or more transformer circuits. configured to increase or decrease the voltage supplied to it through a power module. For example, if a higher voltage power module is attached to a lower voltage port, the 1800 control system can activate, or switch on, a transformer circuit to reduce the voltage of the lower voltage supply module. high. Similarly, if a lower voltage power module is attached to a higher voltage port, the 1800 control system can activate, or turn on, a transformer circuit to increase the voltage of the lower voltage power module. In various embodiments, the 1800 control system is configured to shut down a power module if a power module that has an inadequate voltage is attached to a port on the drive module.
[0301] [0301] In several cases, a power module may comprise a switch that is selectively actuatable by the clinician to prevent the power module from supplying power to the drive module 1100. In at least one case, the switch comprises a mechanical switch, for example in the power supply circuit of the power module. A power module that has been turned off, however, can still provide other benefits. For example, a powered off power module 1200 may still provide a pistol grip and a powered off power module 1300 may still provide a rod grip. Also, in some cases, a power module that is turned off can provide a reserve of energy that can be selectively actuated by the clinician.
[0302] [0302] In addition to or in lieu of the above, each of the power modules 1200 and 1300 comprises an identification memory device. Identification memory devices may comprise a solid-state integrated circuit, for example, which has data stored on it that can be accessed by and/or transmitted to the 1800 control system when a power module is mounted. in the drive module 1100. In at least one case, the data stored in the identification memory device may comprise data regarding the voltage at which the power module is configured to supply the drive module 1100, for example.
[0303] [0303] In addition to the above, each of the drive shaft assemblies 2000, 3000, 4000 and/or 5000 comprises an identification memory device, for example the memory device
[0304] [0304] In addition to the above, an end actuator configured to grasp and/or dissect tissue may require less energy than an end actuator configured to grasp tissue from a patient. As a result, an end actuator and/or drive shaft assembly comprising a clip applicator may have greater power requirements than an end actuator and/or drive shaft assembly comprising grasping and/or dissecting jaws. In such cases, the 1100 power module's 1800 control system is configured to verify that the power module, or modules, attached to the 1100 drive module can supply sufficient power to the 1100 drive module. The 1800 control can be configured to interrogate the identification integrated circuits on the power modules attached to the 1100 drive module and/or to assess the power sources within the power modules to assess whether the power modules understand voltage and/or enough current available to properly power the 1100 drive module to operate the clip applicator.
[0305] [0305] In addition to the above, an end actuator configured to hold and/or dissect tissue may require less energy than an end actuator configured to suture a patient's tissue, for example. As a result, an end actuator and/or drive shaft assembly comprising a suturing device may have greater energy requirements than an end actuator and/or drive shaft assembly comprising gripping jaws and/or or dissection. In such cases, the 1100 power module 1800 control system is configured to verify that the module, or modules,
[0306] [0306] In addition to or in lieu of the above, an end actuator, such as the 7000 end actuator, for example, comprises an identification memory device. The identification memory device of an end actuator may comprise a solid-state integrated circuit, for example, which has data stored therein that can be accessed by and/or transmitted to the 1800 control system when the actuator is end is mounted to the 1100 drive module via a drive shaft assembly. In at least one case, the data stored in the identification memory device may comprise data concerning the energy required to operate the end actuator drive systems. The end actuator may be in communication with the 1100 drive module via electrical paths, or circuits, that extend through the drive shaft assembly. Similar to the above, the end actuator can identify itself to the 1100 drive module and with this information, the 1100 drive module can adapt its operation to properly operate the end actuator.
[0307] [0307] As described above, power modules 1200 and 1300 each comprise one or more battery cells. Said that,
[0308] [0308] The 1200 and 1300 power modules can be rechargeable or non-rechargeable. When the 1200 and 1300 power modules are not rechargeable, they are discarded after a single use. In such cases, it is desirable for the 1200 and 1300 power modules to be completely drained, or at least substantially drained, of power when discarded. For this purpose, each power module comprises a drain which is engaged, or actuated, when the power module is mounted on the drive module.
[0309] [0309] Multiple surgical instruments, including various hand instruments, are used by a physician during a specific surgical procedure to perform different functions. Each surgical instrument may comprise different grip and/or handle configurations, in addition to different user control mechanisms. Switching between multiple handheld instruments can cause a delay and/or discomfort as the clinician regains control over the surgical instrument and triggers the user control mechanism(s). The use of multiple motor-equipped surgical instruments may require a user to ensure that, prior to initiating each surgical procedure, numerous power supplies are charged and/or functional, as power sources may vary and/or may not be available. be compatible with all motor-equipped surgical instruments.
[0310] [0310] A modular surgical instrument comprising a universal grip and power source can provide a clinician with a sense of familiarity with the use of a universal grip configuration. The modular surgical instrument is configured for use with numerous surgical tool fixtures. Rather than having to carry a plurality of different power sources, the modular surgical instrument is configured for use with a replaceable power source that can be discarded after each surgical procedure. Furthermore, the use of a universal grip with a plurality of surgical tool attachments can reduce the clutter and/or volume of surgical instruments within the surgical field.
[0311] [0311] Figure 73 illustrates a portion of a Modular Surgical Instrument 80000 and Figure 74 illustrates an electrical architecture of the Modular Surgical Instrument 80000. The configuration of the Modular Surgical Instrument 80000 is similar in many respects to the Surgical Instrument 1000 in Figure 1 discussed above. The modular surgical instrument 80000 comprises a plurality of modular components, including, for example: a drive module 80010, a drive shaft 80020, an end actuator 80030, and a power source 80040. the 80010 drive module comprises a handle. The 80010 drive module comprises one or more 80012 control switches and an 80015 motor.
[0312] [0312] The 80020 drive shaft comprises an 80022 control circuit configured to facilitate communication between the 80010, 80020, 80030, 80040 modular components of the 80000 surgical instrument. The operation and functionality of the 80010 modular components , 80020, 80030, 80040 of the 80000 surgical instrument are described in more detail above in connection with other surgical instruments.
[0313] [0313] In various cases, the one or more control switches 80012 correspond to the rotation actuator 1420 and the linkage actuator 1430 of the input system 1400 as described in more detail with reference to Figures 7 and 8 above. As shown in Figures 7 and 8, linkage actuator 1430 comprises a first pushbutton 1432 and a second pushbutton 1434. The first pushbutton 1432 comprises a first key that is closed when the first pushbutton 1434 is pressed. . Similar in many respects to the 1430 linkage actuator and 1420 rotation actuator shown in Figures 7 and 8, the one or more control switches 80012 may comprise push buttons. When a user action presses the push button, a switch is closed which sends a signal to the 80022 control circuit indicative of a user command. In many cases, a first push-button can initiate articulation or rotation in a first direction while a second push-button can initiate articulation or rotation in a second direction. The operation and functionality of these 80012 control switches are described in more detail above.
[0314] [0314] In many cases, the 80020 drive shaft is configured to be disposable after being used to treat a patient. In such cases, the 80020 drive shaft can be used more than once on the same patient. As discussed in more detail below, the drive shaft 80020 comprises a processor 80024 and a memory that stores instructions for one or more control programs. The 80020 Disposable Drive Shaft comprises any signal processing circuitry required to interface with the 80030 End Actuator, the 80040 Power Source, and/or the 80010 Drive Module when the 80000 Modular Surgical Instrument is fully configured, or mounted. The 80030 end actuator comprises an 80035 sensor array configured to monitor a parameter of the 80030 end actuator. This 80035 array of sensors can detect, for example, information related to the identity of the 80030 end actuator, an operational state of the actuator 80030, and/or information regarding the surgical site environment, such as tissue properties, for example. In several cases, the 80040 power supply comprises a replaceable battery pack configured to be attached directly to the 80010 drive module to supply power to the 80000 surgical instrument. The 80040 power supply comprises an 80042 battery and an 80044 display. In many cases, the 80044 display comprises a touch screen, for example where a user action is sent to the processor
[0315] [0315] In many cases, the 80010 drive module comprises a power supply interface to attach the 80040 modular power supply to it. The replaceable connection between the 80040 power supply and the 80010 drive module allows a user to readily exchange the 80040 power supply without having to disassemble an 80010 drive module cabinet. The 80042 battery within the 80040 modular power supply comprises a primary cell, but can also include secondary cells. The 80042 primary cell battery is configured to be fully charged once. In other words, the 80042 primary cell battery is configured to be discarded after every surgical procedure. The use of a disposable power supply can, among other things, provide the clinician with reassurance that the 80042 battery is fully charged at the start of each surgical procedure.
[0316] [0316] The power supply interface provides the interconnect between the 80042 battery and the 80044 display connection when the 80040 power supply is attached to the 80010 drive module. In other words, there is no continuous circuit in the 80040 power supply until the 80040 power supply is replaceably attached to the power supply interface on the 80010 drive module. In this way, the 80040 power supply can be dispensed and sterilized in a decoupled state. The ability to be in a decoupled state makes it possible for each 80040 power source to be easily sterilized. For example, the 80040 modular power supply is compatible with both ethylene oxide sterilization and gamma sterilization, as no continuous circuit is present in the 80040 unfixed power supply.
[0317] [0317] Similar to the 80040 power supply, the 80010 drive module has no continuous circuit until it is attached to the 80020 drive shaft and 80040 power supply. At least for this reason, the 80010 drive module can be sterilized using any desired sterilization protocol after each use. In its unfixed configuration, the 80010 drive module is configured to be tolerant of full immersion during the cleaning process.
[0318] [0318] In addition to the above, the 80022 control circuit of the 80020 drive axis comprises a 80024 processor configured to receive a user action from one or more 80012 control switches on the 80010 drive module. The 80020 drive axis additionally comprises an 80028 motor controller configured to control the 80015 motor within the 80010 drive module when the 80020 drive shaft is mounted on the 80010 drive module. In several cases, the 80022 control circuit additionally comprises a safety processor 80024 comprising two controller-based families, such as the TMS570 and RM4x known under the tradename Hercules ARM Cortex R4, also available from Texas Instruments. The 80026 security processor can be configured specifically for security critical applications IEC 61508 and ISO 26262, among others, to provide advanced built-in security features while providing scalable performance, connectivity and memory options. The 80026 safety processor is configured to be in signal communication with the 80024 processor and 80028 motor controller. The 80028 motor controller is configured to be in signal communication with the 80035 sensor array of the 80030 end actuator and the 80015 motor inside the 80010 handle. The 80028 motor controller is configured to send an electrical signal, such as a voltage signal, indicative of the voltage (or power) to be supplied to the 80015 motor. The electrical signal can be determined based on, for example, user action from one or more 80012 control switches, signal received from the 80035 sensor array, user action from the 80044 display, and/or motor feedback 80015. In many cases, the 80028 motor controller can supply a pulse width modulation (PWM) control signal to the 80015 motor to control the 80015 motor.
[0319] [0319] Drive shaft 80020 further comprises a memory configured to store control programs which, when executed, instruct the processor to, among other things, command motor controller 80028 to drive motor 80015 at a predetermined level. The memory within the 80022 control circuit of each 80020 drive axis is configured to store one or more control programs to enable the 80000 Modular Surgical Instrument, when fully configured, to perform a desired function. In various cases, the 80020 drive axis may comprise a standard control program for when the fixed 80020 drive axis does not comprise a control program and/or a stored control program cannot be read or detected. . This standard control program allows the 80015 motor to be operated at a minimum level to allow a clinician to perform basic functions of the modular surgical instrument.
[0320] [0320] Figure 75 shows a drive module 80110 that comprises a plurality of drives configured to interact with corresponding drives on a fixed drive shaft to produce a desired function, such as rotation and/or swivel articulation. an end actuator. For example, the 80110 drive module comprises an 80120 rotation drive configured to rotate an end actuator upon actuation. The 80110 drive module in Figure 75 is configured to operate based on the grip type attached to the modular drive shaft. One or more of the plurality of drives is decoupled when a low-functionality handle, such as a scissor handle grip, is attached to the modular drive shaft.
[0321] [0321] In many cases, the 80120 rotation actuator is in communication with a manual rotation actuator, such as the 1420 rotation actuator, described in more detail above with respect to Figures 8, 10 and 11. As the clinician rotates the actuator of rotation, the position of the rotation actuator can be monitored. For example, the surgical instrument may comprise an encoder system configured to monitor the position of the rotation actuator. In addition to or in place of the encoder system, the 80110 drive module may comprise a sensing system configured to detect a degree of rotation of the rotation actuator. In either case, the sensed position of the rotation actuator is communicated to a processor and a motor controller, such as the
[0322] [0322] The 80024 processor and 80028 motor controller are configured to drive an 80020 drive shaft system unlike the system being manually driven by the 80120 spin drive in response to movement of the spin drive
[0323] [0323] Figure 76 shows an 80210 handle before engagement with an 80220 interchangeable drive shaft. The 80210 handle can be used with multiple interchangeable shafts and can be called a universal handle. The drive shaft 80220 comprises a drive rod 80250 configured to mechanically engage a distal nut 80255 of the handle 80210. A proximal end 80251 of the drive rod 80250 comprises a specific geometry configured to fit within a recess. 80256 defined at the distal end of the distal nut 80255. The recess 80256 within the distal nut 80255 comprises a geometry that is complementary to the geometry of the proximal end 80251 of the drive rod
[0324] [0324] In various instances, the distal end 80211 of the drive nut 80255 and the proximal end 80223 of the drive rod 80250 comprise a plurality of magnetic elements 80260, 80265, 80270 configured to facilitate drive shaft alignment. 80220 with the 80210 grip in addition to or in place of the mechanical alignment system described above. The system of magnetic elements 80260, 80265, 80270 makes it possible to self-align the drive shaft 80220 with the handle 80210. In many cases, the plurality of magnetic elements 80260, 80265, 80270 are permanent magnets. As seen in Figure 75, the proximal end 80223 of the drive shaft 80220 comprises a plurality of magnetic elements 80260 and 80265 that are oriented asymmetrically, although the magnetic elements 80260 and 80265 may be arranged in any suitable manner. The 80260 and 80265 magnetic elements are positioned with the opposite poles facing outward from the 80223 proximal end of the 80220 drive shaft. More specifically, the 80260 magnetic elements positioned over a first portion of the 80220 drive shaft are positioned with their positive poles facing outward from the proximal end 80223, while magnetic elements 80265 positioned on a second or opposite portion of the drive shaft 80220 are positioned with their negative poles facing outward from the 80220 drive shaft.
[0325] [0325] In addition to the above, if the clinician tries to align the 80210 handle with the 80220 drive shaft so that the 80270 magnetic elements positioned on the 80210 handle are in the vicinity of the 80260 magnetic elements positioned on a first portion of the drive shaft 80220, the magnetic elements 80260, 80270 produce an attractive magnetic force, thereby pulling the modular components 80210, 80220 into alignment. However, if the clinician attempts to align the 80210 handle with the 80220 drive shaft so that the 80270 magnetic elements positioned on the 80210 handle are closer to the immediate vicinity of the 80265 magnetic elements positioned on a second portion of the 80220 drive shaft , a repulsive magnetic force will push and separate the modular components 80210, 80220, thus preventing an improper connection between the 80210 handle and the 80220 drive shaft.
[0326] [0326] In certain cases, in addition to the above, there will only be a stable position between the modular components. In various cases, a plurality of magnetic elements are positioned so that their poles alternate in a repeating pattern along the outer circumferences of the distal end of the handle 80210 and the proximal end of the drive shaft 80220. Such a pattern can be created to provide a plurality of stable alignment positions.
[0327] [0327] In several cases, the 80210 grip and 80220 drive shaft comprise a dominant magnetic element that provides an initial attractive magnetic force, with the dominant magnetic elements being configured to approximate the 80210, 80220 modular components one from the other. After the modular components 80210 and 80220 are assembled by the dominant magnetic elements, the plurality of magnetic elements 80260, 80265, 80270 are configured to fine-tune the orientations of the handle 80210 and the drive shaft 80220.
[0328] [0328] Figure 77 shows an 80310 universal grip before being aligned with an 80320 drive shaft and secured thereto. The proximal end 80323 of the 80320 drive shaft comprises a pin 80322 configured to engage a slot 80312 in for-
[0329] [0329] The magnetic elements described above may comprise electromagnets, permanent magnets or a combination thereof. In cases such as those described above, a system of permanent magnetic elements can align the drive shaft and handle in a plurality of positions. In such cases, an electromagnet can be added to the permanent magnetic element system. When activated, the electromagnet is configured to exert a stronger magnetic field than the magnetic fields within the permanent magnetic element system. In other words, an electromagnet can be incorporated to interrupt, thwart, and/or alter cooperation between the permanent magnet system. This interruption results in the ability to exert selective control over the alignment of the modular components of the surgical instrument. For example, when a system of magnetic elements, such as the magnetic elements 80260, 80265, and 82070 in Figure 76, has placed the 80220 drive shaft and the 80210 handle in a properly aligned position, the clinician can selectively activate a electromagnet to produce a magnetic field strong enough to overcome the attractive magnetic forces of permanent magnets and repel the drive shaft in the opposite direction of the grip. In many cases, activating the electromagnet pushes the handle away from the drive shaft to release and unlock the handle drive shaft. In many cases, the activation of the electromagnet is configured not only to disturb the attraction created by the permanent magnets but also to decouple the 80210 and 80220 modular components.
[0330] [0330] A modular surgical instrument, such as the 80000 surgical instrument shown in Figure 73, for example, comprises a plurality of components configured to communicate with each other in order to perform an intended function of the surgical instrument. The communication paths between the components of the modular surgical instrument are described in detail above. While such communication routes may be wireless in nature, wired connections are also suitable. In many cases, the end actuator and/or drive shaft of the surgical instrument are configured to be inserted into a patient through a trocar, or cannula, and can be of any suitable diameter, such as approximately 5 mm, 8 mm, and/or or 12 mm, for example. In addition to size restrictions, many modular surgical instruments, such as a clip applicator, comprise end actuators and/or drive shafts that are configured to rotate and/or pivot, for example. As such, any wired communication path needs to be compact and have the flexibility to maintain functionality as the end actuator and/or drive shaft is rotated and/or pivoted. In an effort to reduce the size of operating elements within a drive shaft and/or actuator end of a surgical instrument, various functional electromechanical microelements can be utilized. The incorporation of micro electronic components, for example a piezoelectric inchworm actuator or a "squiggle" motor, in a surgical instrument helps to reduce the space required for operating elements, as a squiggle motor, for example, is configured to provide linear motion. no gears or cams.
[0331] [0331] In many cases, flexibility is created in the wired communication path(s) by mounting multiple electrical tracks onto a flexible substrate. In many cases, the electrical tracks are supported over the flexible substrate in any suitable way. Figure 79 shows a flexible circuit 80400 for use in a modular surgical instrument, such as the surgical instrument 1000, for example. The 80400 flexible circuit is configured to extend within a drive shaft housing, such as the 80020 drive shaft of Figure 73. A distal end 80401 of the 80400 flexible circuit is configured to be electrically coupled to the electrically conductive tracks within the 80400 flexible circuit. end actuator. In at least one case, the electrical tracks are comprised of copper and/or silver, for example. The distal end 80401 is wrapped around a first ring 80402, and electrical tracks 80405 extend around the first ring 80402. A proximal end 80403 of the flexible circuit 80400 is configured to be electrically coupled to electrical tracks within a handle. The proximal end 80403 is wrapped around a second ring 80404, and electrical trails 80405 extend around the second ring 80404.
[0332] [0332] While the support of multiple electrical tracks on the flexible substrate provides flexibility, additional features can be added to, among other things, increase the longevity and/or protect the integrity of the 80400 flexible circuit. As depicted in Figs. At ras 79 and 79A, a primary stress relief region 80410 is configured to be positioned proximal to a pivot joint.
[0333] [0333] As seen in Figures 79 and 79B, the flexible circuit 80400 is produced with a secondary stress relief region 80420 whose conductive elements 80405 are separate and not interconnected. This orientation of the 80405 conductive elements makes it possible for the 80400 flexible circuit to be bent. The non-fatigue and flexible portions of the 80400 flexible circuit are positioned perpendicular to the 80400 flexible circuit within the 80410 primary stress-relief region. The 80420 secondary stress-relief region comprises one or more members. 80422 propensity members, similar to the 80412 propensity members described in more detail above. The presence of bias members 80412 within the primary stress relief region 80410 and bias members 80422 within the secondary stress relief portion 80320 enables the flexible circuit 80400 to have an extendable portion in at least two planes separated in relative to a longitudinal axis of the drive shaft, such as drive shaft 80020 of Figure 73, for example. The presence of the primary strain relief portion 80410 in the foreground and a secondary strain relief portion 80320 in the background enables communication between an end actuator, a drive shaft assembly, and a handle. of a surgical instrument configured to pivot the end actuator, rotate the end actuator, and rotate the drive shaft assembly. In another case, the flexible circuit 80400 may be fabricated flat and subsequently braided into a portion, such as the primary stress relief region 80410, which correlates with the articulation or actuation portion of the surgical instrument. This design can alleviate the need for stress relief for the 80400 flexible circuit in general.
[0334] [0334] Figure 79C shows a portion of the flexible circuit 80400 of Figure 79 characterized by a printed circuit board (PCB) formed integrally with the flexible substrate 80430 of the flexible circuit.
[0335] [0335] Figure 80 shows an 80500 end actuator flexible circuit configured to extend inside an end actuator. The 80500 end actuator flexible circuit is configured for use with a drive shaft flexible circuit, such as the 80400 flexible circuit shown in Figures 79 through 79C. The 80500 end actuator flexible circuit comprises 80505 electrical tracks supported on a flexible substrate. A distal 80503 end of the 80500 end actuator flexible circuit is wound onto an 80504 ring. The 80505 electrical tracks extend around the 80504 ring. As shown in Figures 81A and 81B, the 80504 ring is configured to be electrically coupled to the flexible drive shaft circuit, for example via the first ring 80402 at the distal end 80401 of the flexible circuit 80400. One or both of the flexible circuits 80400 and 80500 comprise biasing members to maintain electrical contact between the tracks at the interface between the 80400, 80500 flexible circuits. In many cases, the 80500 end actuator flexible circuit comprises one or more sensors, such as an 80510 clip feed sensor and/or a clip cam the 80510 power clip and/or an 80520 clip cam sensor. Such sensors can detect an end actuator parameter and communicate the detected parameter to the components of the end actuator. control circuit 80432, 80434, 80436 in flexible drive shaft circuit
[0336] [0336] Referring to Figure 82, a surgical instrument 215000 comprises a handle 215100, a drive shaft assembly 215500 secured to the handle 215100, an end actuator 215600 and a pivot joint 215550 pivotally connecting the end actuator 215600 to the 215500 drive shaft assembly. The 215100 handle includes a 215200 drive system, a 215300 power supply, and an actuator
[0337] [0337] In addition to the above, the second drive motor 215250 comprises a swivel input drive shaft and an input gear 215255 fixedly mounted to the swivel input drive shaft. The second shifter motor 215260 comprises a shifter drive shaft and a 215265 pinion gear rotatably mounted to the shifter drive shaft. The pinion gear 215265 is operationally interleaved with the input gear 215255 of the second drive motor 215250 and is translatable between a first and a second position by the second displacer motor.
[0338] [0338] In addition to the above, again referring to Figure 83, the output drive shafts 215230, 215240 and 215280 comprise rigid drive shafts and are nested concentrically. In several cases, one bearing is present between the output drive shaft 215230 and the output drive shaft 215240 and another bearing is present between the output drive shaft 215240 and the output drive shaft 215280. In In other cases, the output drive shafts 215230, 215240 and 215280 are directly supported by each other. Such arrangements can provide a compact design. In several alternative embodiments, none of the output drive axes 215230, 215240, and 215280 are nested.
[0339] [0339] Referring to Figure 84, a 216200 alternative drive system is configured to drive a total of six functions of a surgical instrument. Similar to the above, the drive system 216200 comprises a first drive motor 216210, a first drive motor 216220, a second drive motor 216250, and a second drive motor 216260. The first drive motor 216210 comprises a shaft input drive shaft and a 216215 input gear fixedly mounted to the rotary input drive shaft. The first displacer motor 216220 comprises a displacer drive shaft and a 216225 pinion gear rotatably mounted to the displacer drive shaft. Pinion gear 216225 is operationally interleaved with input gear 216215 of first drive motor 216210 and is translatable between first, second and third positions by first shifter motor 216220. When pinion gear 216225 is in its In the first position, the pinion gear 216225 is operatively interleaved with the input gear 216215 and with an output gear 216235 fixedly mounted to a rotating output drive shaft 216230. In such cases, the rotation of the first drive motor 216210 is transferred to the rotary output drive shaft 216230 when the first drive motor 216210 is operated. When pinion gear 216225 is in its second position, pinion gear 216225 is operationally interleaved with input gear 216215 and with output gear 216245 fixedly mounted to a rotating output drive shaft 216240. In these cases, the rotation of the 216210 first drive motor is transferred to the rotating output drive shaft
[0340] [0340] In addition to the above, the output drive shaft 216230 is operatively engaged with a drive shaft 216500 of the surgical instrument so that the rotation of the output drive shaft 216230 is transferred to the drive shaft
[0341] [0341] In addition to the above, the second drive motor 216250 comprises a swivel input drive shaft and a 216255 input gear fixedly mounted to the swivel input drive shaft. The second displacer motor 216260 comprises a displacement drive shaft and a pinion gear.
[0342] [0342] In addition to the above, the 216270 Output Drive Shaft and/or the 216280 Output Drive Shaft can be operatively coupled to a Grapple Grip Drive, to a Fire Drive System, such as a triggering of staples and/or to a fabric cutting drive, for example, and/or to an end actuator rotation drive, for example. The output drive shaft 216290' is operatively engaged with a second pivot drive 216800. The second pivot drive 216800 comprises two 216890 translateable pivot drives, each of which is coupled to a translatable drive nut 216895 engaged. threaded to output drive shaft 216290'. Each drive nut 216895 comprises a pin, or projection, which extends into a thread or groove defined in the output drive shaft 216290' and which is prevented from rotating such that rotation of the output drive shaft 216290' displaces drive nuts 216895. In use, the output drive shaft 216290' is rotated in a first direction to rotate a surgical instrument end actuator around a second pivot joint in one direction and rotated in a opposite direction to rotate the end actuator around the second swivel joint in the other direction. The thread defined on the output drive shaft 216290' is configured to push one of the drive nuts 216895 and the pivot drivers 216890 distally while pulling the other drive nut 216895 and the pivot driver 216890 proximally. That said, a drive nut and the 216895 pivot driver may be sufficient to pivot the end actuator around the second pivot joint.
[0343] [0343] As described above, the first drive motor
[0344] [0344] In addition to the above, the 216220 first displacer motor can be configured to lock the two uncoupled drive shafts when it operatively couples a drive shaft to the 216210 first drive motor. In at least one of these cases, the The translatable drive shaft of the first displacer motor 216220 may comprise latches defined therein that are configured to engage and lock the two uncoupled drive shafts in position. In at least one case, the first shifter motor 216220 locks the drive shaft 216230 and 216240 when it operatively engages the first drive motor 216210 with the drive shaft 216290. Similarly, the second shifter motor 216260 can be configured to lock the two uncoupled drive shafts when it operatively couples a drive shaft to the second drive motor 216250. In at least one of these cases, the translatable drive shaft of the second displacer motor 216260 comprises locks defined in the same as are configured to engage and lock the two uncoupled drive shafts in position. In at least one case, the second displacer motor 216260 locks the drive shaft 216270 and 216280 when it operatively engages the second drive motor 216250 with the drive shaft 216290'. In such cases, end actuator functions that are not engaged are positively disabled or latched. That said, arrangements are envisaged in which the end actuator functions do not need to be locked when not in use or coupled to a drive motor. In either case, the first displacer motor 216220 and/or the second displacer motor 216260 may comprise a solenoid, for example, to create the longitudinal displacement of their drive shafts.
[0345] [0345] As described above, the 215200 drive system is configured to drive four instrument functions and the 216200 drive system is configured to drive six instrument functions. That said, a drive system for the instruments disclosed herein can be configured to drive any suitable number of functions, such as more than six end actuator functions, for example.
[0346] [0346] In addition to the above, a surgical instrument motor control system can adapt the operation of one or more surgical instrument motors. Referring to Figure 85, the 215000 surgical instrument comprises a 215900 strain gauge circuit that is in communication with the 215000 surgical instrument motor control system. The 215900 strain gauge circuit comprises a 215910 strain gauge mounted in the housing, or gabi- nete, 215510 of drive shaft 215500. The strain gauge 215910 comprises a base 215920, a first electrical contact 215930 on base 215920, a winding electrical circuit 215940 in electrical communication with the first electrical contact 215930, and a second electrical contact 215950 in electrical communication with electrical circuit 215940. Electrical contacts 215930 and 215950 are configured to be soldered, and/or otherwise electrically coupled, to conductive wires and/or conductive tracks, for example, to place the strain gauge 215910 communicating with the engine control system. The 215940 electrical circuit is comprised of a thin conductive wire whose resistance changes when the 215910 strain gauge is extended and/or compressed, as discussed in more detail below.
[0347] [0347] Again with reference to Figure 85, the base 215920 of the strain gauge 215910 is mounted on the housing 215510 so that the strain gauge 215910 elongates when the shell 215510 is placed under tension and contracts when the shell 215510 is compressed. Referring to Figure 85A, the resistance of electrical circuit 215940 changes, that is, it increases when strain gauge 215910 is placed under tension along a longitudinal axis L, which is detectable by the motor control system. Similarly, with reference to Figure 85B, the resistance of electrical circuit 215940 changes, i.e. it decreases when strain gauge 215910 is compressed along the longitudinal axis L, which is also detectable by the motor control system. . The change of the
[0348] [0348] In addition to the above, the 215000 Surgical Instrument Motor Control System can adaptively control the speed of one or more electric motors. The motor control system comprises one or more pulse width modulation (PWM) circuits, and/or any other power control circuit, to control the speed of electric motors. A pulse width modulation (PWM) circuit is configured to apply voltage pulses to an electric motor to drive the electric motor at a desired speed:
[0349] [0349] In addition to or instead of adapting the voltage supplied to the electric motors of the 215000 surgical instrument to control the speed of the motors, the current supplied to the electric motors can be adapted to control the driving force provided by the electric motors. For this purpose, a surgical instrument may include one or more motor current control circuits.
[0350] [0350] The 215910 strain gauge is an axial strain gauge that is well suited for measuring strain along the longitudinal axis L; however, a 215910 strain gauge may not provide a full understanding of the stress occurring on the 215510 sheath. Additional strain gauges situated adjacent to the 215910 strain gauge that are oriented in different directions may provide additional data regarding the strain occurring at that position. For example, another strain gauge may be positioned orthogonally to strain gauge 215910 along the transverse axis T and/or at a 45 degree angle to the longitudinal axis L, for example. Various arrangements are envisaged in which more than one strain gauge is provided on a single strain gauge base. Such an arrangement can provide greater resolution of stress at a specific location. As stated above, any suitable strain gauge can be used. For example, capacitive strain gauges, semiconductor strain gauges, nanoparticle strain gauges, and/or fiber optic strain gauges, for example, could be used.
[0351] [0351] When one or more resistance strain gauges are attached to a surface to measure strain, as discussed above, the strain gauges can be arranged in a Wheatstone bridge circuit, as illustrated in Figure 85C. A Wheatstone bridge is a split bridge circuit used for the measurement of static or dynamic electrical resistance. The output voltage of the Wheatstone bridge is often expressed in millivolts of output per volt of input. Referring to Figure 85C, if R1, R2, R3, and R4 are equal, and a voltage, VIN, is applied between points A and C, then the output between points B and D will show no potential difference. However, if R4 is changed to some value that is not equal to R1, R2 and R3, the bridge will be unbalanced and there will be voltage across the output terminals. In a G-bridge configuration, the variable strain sensor has resistance Rg, while the other arms are fixed value resistors.
[0352] [0352] A strain gauge sensor, however, can occupy one, two or four arms of the Wheatstone bridge. The total effort, or output voltage (VOUT) of the circuit is equivalent to the difference between the voltage drop across R1 and R4, or Rg. The bridge is considered balanced when R1/R2 = Rg/R3 and therefore VOUT is equal to zero. Any small change in the resistance of the detection grid will put the bridge out of balance, making it suitable for stress detection. When the bridge is configured so that Rg is the only active strain gauge, a small change in Rg will cause an output voltage on the bridge.
[0353] [0353] The number of active strain gauges that must be connected to the bridge depends on the application. For example, it may be useful to connect strain gauges that are on opposite sides of the surgical instrument case or wrap, one in compression and the other in tension. In this arrangement, the bridge output for the same effort is effectively doubled. In installations where all four arms of a Wheatstone bridge are connected to strain gauges, temperature compensation is automatic, as the change in resistance due to temperature variations will be the same for all four arms of the bridge. of Waterstone.
[0354] [0354] In a four-element Wheatstone bridge, in addition to the above, generally two strain gauges are wired in compression and two in tension, but any suitable arrangement can be used. For example, if R1 and R3 are in tension (positive) and R2 and R4 are in compression (negative), then the output will be proportional to the sum of all mechanical stresses measured separately. For strain gauges situated on adjacent legs of the Wheatstone bridge, the bridge is unbalanced in proportion to the difference in effort. For strain gauges situated on opposite legs of the Wheatstone bridge, the bridge balances in proportion to the sum of the mechanical stresses. Whether the measurement is performed on flexural stress, shear stress, or torsional stress, the strain gauge layout will determine the relationship between the output and the type of stress being measured. As shown in Figure 85C, if a positive strain occurs on strain gauges R2 and R3 and a negative strain is experienced on strain gauges R1 and R4, the total output, VOUT, would be four times the resistance of a single strain gauge.
[0355] [0355] Other strain gauge circuits may be used in addition to or in place of the Wheatstone bridges discussed above. Constant current and/or constant voltage arrangements could be used, for example.
[0356] [0356] As described above, the data provided by the one or more strain gauges to the motor control system can be used to modify the operation of one or more electric motors of the surgical instrument. In addition to or instead of decelerating an electric motor, the motor control system can stop an electric motor. In at least one case, the motor control system uses two or more effort limits whereby the motor control system decelerates the electric motor when the measured effort exceeds a first limit but stops the electric motor when the measured effort exceeds a first limit. second limit, or a higher limit. In certain cases, the motor control system will decelerate the electric motor when the measured effort exceeds a first threshold and further decelerate the electric motor when the measured effort exceeds a second or higher threshold. In many cases, the engine control system can be configured to accelerate an electric motor and/or restore the electric motor to its original speed when the measured effort drops below one or more of the exceeded limits. In either case, the motor control system is configured to receive additional data from a central surgical controller outside the instrument relating to determining the proper reaction to a high stress state. In addition, the motor control system is configured to transmit data to the central surgical controller which can store and/or analyze the stress data and output a feedback signal regarding the appropriate reaction to a high stress state. For this purpose, the surgical instrument 215000 comprises a wireless signal transmitter and a wireless signal receiver; however, wired modalities are provided.
[0357] [0357] In addition to the above, it should be understood that it is important to obtain accurate stress readings.
[0358] [0358] In many cases, in addition to the above, force measurement is an excellent surrogate for determining the forces a surgical instrument is experiencing. That said, such strain measurements do not directly measure these forces. In various embodiments, the 215000 surgical instrument comprises one or more force sensors positioned adjacent to the 215910 strain gauge to directly measure forces. In at least one instance, a force sensor comprises a spring element that is extended and/or contracted along a geometric axis that is parallel, or at least substantially parallel, to the longitudinal axis of the strain gauge 215910. The force sensor is in communication with the motor control system and as a result the motor control system can use both strain gauge data and force sensor data to adapt the operation of the surgical instrument motors. .
[0359] [0359] In addition to the above, mechanical stresses and/or forces within the 215510 drive shaft housing of the 215500 Surgical Instrument are measurable to control the operation of the 215500 Surgical Instrument. Increased stress and/or force on the drive shaft housing 215510 suggests that the drive shaft of the surgical instrument 215500 may be pressed against the patient's tissue. To make the physician aware of the force being applied to the patient's tissue, the 215500 surgical instrument additionally comprises an indicator in communication with the 215500 surgical instrument control system that is activated by the control system when the effort measured by the strain gauges in the 215510 drive shaft wrap exceeds a threshold level. The indicator may comprise a light configured to create visible feedback, a speaker configured to create audible feedback, a vibrating motor configured to create tactile feedback, and/or an icon on a display screen, for example. In certain cases, the control system may reduce the speed of the motor, or motors, on the 215500 Surgical Instrument when the limit effort is exceeded. Controlling the electric motors in this way can prevent excessive deflection and/or breakage of the 215500 surgical instrument, especially when a part of the 215500 surgical instrument is swiveling and/or rotating, for example. In at least one case, strain gauges and/or force sensors may be positioned on and/or on a circuit board within the surgical instrument 215500, as a flexible circuit, for example. In such cases, as a result, an excessive force/deflection load within the circuit, especially the circuit mounted in the surgical instrument cabinet, can be avoided. That said, mechanical stresses and/or forces within a moving component, such as a rotating drive shaft and/or translatable drive member, could also be measured. Such an arrangement enables the motor control system to directly assess mechanical stresses and/or forces within the 215500 surgical instrument drive systems and prevent electric motors and/or drive components from being overloaded.
[0360] [0360] That said, a surgical instrument can utilize a strain gauge in any suitable location. In various cases, a strain gauge circuit may comprise a strain gauge positioned over the grip of an end actuator. Among other things, such a strain gauge can detect gripper deflection, especially when positioned at the distal end of the gripper. With this data, the motor control system can adapt the operation of the surgical instrument to accommodate a jaw flexed beyond the limit, for example. In at least one of these cases, the motor control system can decelerate the electric motor used to drive a distally movable tissue cutting knife, such as a surgical stapler knife, for example. In use, a gripper will deflect elastically when tissue is captured between the end actuator grips, but the grip can sometimes deflect plastically or permanently. A strain gauge positioned on the grip will enable the engine control system to detect that the grip has been permanently damaged when the gripper is released. If permanent damage is above a threshold, the motor control system may limit the functionality of the surgical instrument in some way and/or indicate to the user that the surgical instrument has been damaged and/or indicate the degree of damage.
[0361] [0361] In addition to the above, a strain gauge from a strain gauge circuit can be placed on the grip of a surgical stapler that supports a staple cartridge. When the surgical stapler jaws are engaged, the strain gage can detect stress within the cartridge jaw that can disclose jaw deflection. In this sense, the deflection of the claw can disclose the distance between the claws, or the fabric gap. With this information, the motor control system can assess the thickness of the fabric between the grips and control the speed of the drive motor that drives the fabric cutting knife. For example, the motor control system can slow down the drive motor when the fabric is thick and/or speed up the drive motor when the fabric is thin. In addition to or in place of the above, a strain gauge of a strain gauge circuit may be placed on the tissue cutting knife. Such an extensometer can provide tissue thickness and/or density data to the motor control system. Similar to the above, the motor control system can decelerate the drive motor when the fabric is dense and/or accelerate the drive motor when the fabric is less dense, for example. In addition, the motor control system can stop and/or pause the drive motor which closes the end actuator grip when the measured effort has reached a limit. In many cases, fluid in the trapped tissue needs time to flow out of the tissue at the end actuator after the end actuator is initially trapped, and if the effort drops below the threshold, the motor control system can be configured. to reset the closing drive motor to compress the fabric by a desired amount. Such a strain gauge can be placed on one of the end actuator grips and/or on the closing drive member, for example.
[0362] [0362] The surgical instruments described here can be inserted into a patient through a trocar, such as the Trocar 219900 illustrated in Figure 82C. A trocar may comprise a long drive shaft 219910 comprising a longitudinal opening 219920 extending therethrough, a sharp distal end 219930 configured to be pushed through an incision in the patient, and a proximal end 219940 comprising a port or sealable opening configured to receive a surgical instrument S. In use, the surgical instrument is passed through the sealable port, through the longitudinal opening, and into a patient's body cavity. The sealable port comprises a seal configured to prevent, or at least reduce, the flow of insufflation gas from the patient's body cavity through the trocar. The seal is configured to protrude in a closed, or at least substantially closed, configuration. Even when a surgical instrument extends through the sealable port, the seal is biased against the sides of the surgical instrument to create a sealed, or at least substantially sealed, interface between them. In use, the trocar is orientable within the incision to allow the surgical instrument to be properly oriented within the body cavity. In many cases, the physician using the surgical instrument pushes or pulls the surgical instrument in a desired direction to orient the surgical instrument, and in such cases, the surgical instrument comes into contact with the side walls of the longitudinal opening that also guides the trocar.
[0363] [0363] In several cases, in addition to the above, the trocar applies forces to the patient's tissue when the trocar is guided by the surgical instrument. Excessive forces can pinch, injure, and/or otherwise damage tissue. For this purpose, a trocar may comprise one or more force sensing circuits and/or one or more strain gauge circuits configured and positioned to sense the forces applied to the trocar by the surgical instrument. In many cases, a force sensing circuit is integrated into a flexible substrate, such as a tape, for example, positioned inside the longitudinal opening of the trocar. In at least one of these cases, the flexible substrate extends around the inner circumference of the trocar drive shaft and is secured to the trocar drive shaft by, for example, one or more adhesives. The force sensing circuit comprises one or more transducers supported within the flexible substrate that are compressed by the surgical instrument when the surgical instrument is pushed against the trocar. A transducer, such as a piezoelectric transducer, for example, converts mechanical energy into electrical energy, and when the transducer is compressed between the surgical instrument and the side wall of the trocar, the force sensing circuit generates a voltage potential. . The trocar additionally comprises a control system in electrical and/or signal communication with the force sensing circuits that is configured to detect the voltage potential, and the magnitude of the voltage potential, created by the transducers in the force sensing circuits. .
[0364] [0364] In addition to the above, the Trocar Control System uses an algorithm to determine if the voltage potentials of the force sensing circuits exceed one or more thresholds. The trocar additionally comprises at least one tactile feedback generator, such as a light, a loudspeaker, and/or an eccentric motor, for example, in communication with the control system and, when a voltage potential of a circuit When the force sensor exceeds a predetermined threshold, the control system can trigger the tactile feedback generator to indicate to the clinician that excessive force may be applied to the patient's trocar and tissue through the surgical instrument.
[0365] [0365] In addition to the above, the trocar may comprise a wireless signal transmitter in communication with the trocar control system. The wireless signal transmitter is configured to emit one or more signals that include data relating to force sensing circuits, especially when a threshold has been exceeded. The surgical instrument inserted through the trocar may comprise a wireless signal receiver in communication with the surgical instrument control system which is configured to receive wireless signals from the trocar and relay the signals, or data transmitted by the signals, to the instrument's control system. The surgical instrument additionally comprises at least one tactile feedback generator, such as a light, a speaker, and/or an eccentric motor, for example, in communication with the instrument's control system and, when a voltage potential of a force sensing circuit exceeds a predetermined threshold, the instrument's control system can trigger the tactile feedback generator to indicate to the clinician that excessive force may be applying to the patient's trocar and tissue through of the surgical instrument.
[0366] [0366] In addition to the above, the trocar and surgical instrument may be part of a central surgical controller system. In many cases, the trocar and surgical instrument communicate with the central surgical controller system instead of communicating directly, as discussed above.
[0367] [0367] Trocar force sensing circuitry can be used to assess other information pertaining to the surgical instrument. In at least one case, the trocar control system may determine that a surgical instrument is present in the trocar when the voltage potential of one or more force sensing circuits changes. In many cases, the trocar control system can determine the direction in which the surgical instrument is being pushed. When force sensing circuits on one side of the trocar change voltage potential and force sensing circuits on the opposite side of the trocar do not change voltage potential, or have less change in voltage potential , the trocar control system can determine the direction in which the surgical instrument is being pushed. In certain cases, the trocar may comprise a proximal set of transducers and a distal set of transducers that can be used to assess the orientation of the surgical instrument in the trocar. When proximal transducers on a first side of the trocar have a higher voltage potential than proximal transducers on a second, or opposite, side of the trocar and distal transducers on the second side have a higher voltage potential than the distal transducers on the first side, the trocar control system can determine that the surgical instrument is oriented in the second direction within the patient, for example. Such proximal and distal transducers can also be used to assess the torque that the surgical instrument is applying to the patient's trocar and/or tissue.
[0368] [0368] In addition to the above, the circuits within the trocar and circuits within the surgical instrument can be inductively coupled. In many cases, one or more trocar circuits comprise windings extending around the trocar drive shaft that generate a field within the trocar that interacts with one or more circuits in the surgical instrument. In at least one of these cases, the trocar circuits comprise copper wires integrated into the trocar housing, for example, and the surgical instrument circuits comprise copper wires extending through the operating shaft of the surgical instrument. In such cases, the trocar may transmit power to the surgical instrument and/or wireless data signals to the surgical instrument through this inductive coupling. The trocar may have its own power supply and/or may receive power from the central surgical controller system in the operating room. Alternatively, the surgical instrument circuitry can be configured and arranged to communicate electrical power and/or signal data wirelessly to the trocar. In these cases, the sensors, the control system and/or the tactile feedback generators can be powered by the surgical instrument positioned in the trocar. In certain cases, the trocarte may enter a low power mode, or suspend mode, after not being used for a predetermined period of time. The insertion of a surgical instrument into the trocar can be detected by the trocar control system through these inductive circuits that can cause the trocar to enter a full power or activation mode. . The insertion of a surgical instrument into the trocar can be detected by the instrument control system through these inductive circuits that can cause the instrument to enter a full power, or activation, mode.
[0369] [0369] In any case, the discussion provided above regarding the interaction between a trocar and a surgical instrument is applicable to hand-held surgical instruments and/or surgical instruments operated by a robotic surgical system.
[0370] [0370] Referring to Figure 86, the 215000 surgical instrument comprises a 215700 motor control system. The 215700 motor control system comprises a first circuit board, namely the 215710 flexible circuit, and as described in more detail below, a second circuit board i.e. printed circuit board (PCB)
[0371] [0371] The flexible base comprises polyimide and/or polyether ether ketone (PEEK), for example, and may comprise any suitable number of layers. Conductive tracks are comprised of copper, silver and/or conductive polyester, for example. The conductive tracks are positioned between the layers of the flexible base and/or integrated within the flexible base and are exposed at specific and predetermined locations on the 215710 flexible circuit. The exposed portions of the conductive tracks are at least partially covered with a solder coating. , like tin and/or like silver, for example, and/or a flux coating, like an organic flux, for example. The flexible circuit 215710 additionally comprises electronic components mounted on the surface thereof. These surface-mounted electronic components are mechanically and electrically bonded to the exposed portions of the conductive tracks of the 215710 flexible circuit through soldered connections. Surface-mounted electronics can be quickly mounted on the 215710 flexible circuit using a reflow soldering process, for example. In addition to or in place of surface-mounted components, the 215710 flexible circuit may include electronic components having electrical contacts with through holes. In such cases, the conductive tracks include openings or through holes that are configured to receive electrical contacts or pins extending from the electronic devices. These pins can be soldered to the conductive tracks using a reflow soldering process and/or a wave soldering process, for example. In addition to soldered electrical connections, electronic components can be mechanically bonded to the flexible base to reduce the possibility of soldered connections being subjected to overload.
[0372] [0372] In addition to the above, the 215710 flex circuit is mounted in the 215110 grip cabinet using one or more adhesives so that the bottom surface of the 215710 flex circuit is fitted to the 215110 grip cabinet. flexible 215710 may also be at least partially integrated into the 215110 handle housing. In at least one of these cases, the 215110 handle housing is comprised of plastic that is injection molded onto at least a portion of the flexible circuit. 215710. In certain cases, conductive tracks can be directly attached and/or integrated into the 215110 grip housing without a flexible circuit board. For example, the 215760 conductive tracks are defined in the 215510 grip cabinet that are in electrical communication with the 215160 electrical contacts. When the 215110 grip cabinet sides are mounted together, the 215160 electrical contacts on one side of the 215110 grip housing are electrically connected to the corresponding electrical contacts on the other side. In either case, the conductive tracks have portions that are exposed so that electrical connections can be made with the conductive tracks.
[0373] [0373] In use, in addition to the above, the 215300 power source supplies power to the 215700 engine control system. The 215300 power source comprises one or more direct current (DC) batteries, but may comprise any power source. suitable power such as an alternating current (AC) power source, for example. The 215300 power source may comprise a voltage transforming circuit to provide a desired voltage potential to the 215700 motor control system via electrical wires, or leads, 215750. Notably, the 215750 leads are connected to a second 215720 circuit board of the engine control system
[0374] [0374] In addition to the above, the second circuit board 215720 comprises a card that includes a substrate and electronic components.
[0375] [0375] In view of the above, the first circuit board 215710 is designed to have low power circuits and to transmit lower electrical power loads than the second circuit board 215720 which is designed to have high power circuits. potency. Low power circuits include signal circuits and/or sensor circuits, such as circuits that are responsive to commands from the 215100 handle and/or strain gauge circuits, for example. High power circuits include motor control circuits which may comprise PWM and/or FM control circuits, for example. Other high power circuits include a radio frequency (RF) generator circuit and/or a transducer drive circuit configured to create a standing wave in an end actuator, for example.
[0376] [0376] In addition to the above, the first circuit board 215710 and/or the second circuit board 215720 comprise memory devices configured to store data regarding the operation, status, and/or condition of the surgical instrument 215000, for example . Referring to Figures 82A and 82B, the first circuit board 215710 comprises at least one data access terminal and/or contact 215170 that can be used by a physician to access data stored in memory devices. For this purpose, the 215110 handle housing comprises an access port 215180 configured to allow a connector and/or probe 215880 to be inserted therethrough to operatively connect to the data access terminal 215170. Accessory 215180 comprises a seal that includes an elastomeric portion comprised of rubber, for example, and a sealed, but openable, opening that extends through the elastomeric portion. The opening is biased in the closed, or at least substantially closed, position by the elastomeric material of the seal and may be opened to enable probe 215880 to be inserted therethrough. When probe 215880 is removed from access port 215180, the seal can reseal itself.
[0377] [0377] In addition to or in lieu of the above, the grip housing comprises a pierceable portion 215110 which is configured to be pierced by an electrical probe, for example. The pierceable portion may comprise a thinned portion of the 215110 handle housing that can be readily pierced by the electrical probe to access the circuit boards and/or the motor control system in the 215110 handle housing. In this case, the 215110 handle housing comprises a demarcation indicating where the 215110 handle housing can be drilled. In at least one case, the demarcation comprises a colored zone in the grip housing 215110, for example.
[0378] [0378] Referring to Figures 88 and 89, a 215500' drive shaft assembly is similar to the 215500 drive shaft assembly in many respects. Like the 215500 drive shaft assembly, the 215500' drive shaft assembly forms a swiveling interface with a handle, such as the 215100 handle, for example, which enables the 215500' drive shaft assembly to rotate around a longitudinal geometric axis. The 215500' drive shaft assembly comprises a flexible circuit mounted within the 215510' handle housing, or wrap, that extends around the entire circumference of the 215510' drive shaft housing and comprises 215520 annular electrical contacts. '. The grip comprises a 215700' motor control system that includes a 215710' printed circuit board (PCB). The 215710' PCB comprises 215720' electrical contacts that are engaged and in electrical communication with the 215520' annular electrical contacts. Each 215720' electrical contact comprises a base seated on the 215710' PCB and a pliable or spring member prone to engagement with a 215520' annular electrical contact so that the 215720' electrical contacts are in electrical communication with the 215520 annular electrical contacts ' regardless of the position in which the 215500' drive shaft assembly is rotated relative to the handle. The drive shaft assembly 215500' additionally comprises wires or conductors 215530' which place electrical contacts 215520' in electrical communication with an electric motor 215200'. As a result of the above, the electric motor 215200' on the drive shaft assembly 215500' can be powered by a power source in the handle. In addition, the interface between electrical contacts 215520' and 215720' can transmit signals between the 215500' drive shaft assembly and the handle. This arrangement may enable the motor control system in the grip to communicate with one or more sensors, such as strain gauges and/or force sensors, for example on the 215500' drive shaft assembly, for example.
[0379] [0379] Referring to Figure 90, a 217100 grip is similar to the 215100 grip in many respects. Among other things, the 217100 handle comprises a 217110 handle housing, a drive system comprising at least an electric motor and an engine control system, a 217300 removable battery configured to supply power to the engine control system tor, and a 217400 actuation trigger which, when actuated, closes an end actuator of the drive shaft assembly attached to the 217100 handle. In many cases, the electric motor is configured to drive an end actuator function , such as closing the end actuator, for example. To the extent that other motorized functions are required, in such cases the 217100 Handle may include other drive motors configured to drive these other end actuator functions. Alternatively, a drive motor can be used to drive more than one end actuator function as described above.
[0380] [0380] Again with reference to Figure 90, handle 217100 additionally comprises controls 217140, 217150 and 217160 which are in communication with the motor control system of handle 217100. Control 217130 is actuatable to operate an electric motor on handle 217100 which pivots the end actuator with respect to a longitudinal axis of the drive shaft assembly attached to the 217100 handle. Referring to Figure 92, the 217130 control comprises an oscillator knob that includes a knob housing 217132. Oscillator knob 217132 comprises a first casing portion 217131 and a second casing portion 217133 which are separated by a recessed groove 217135 defined in the oscillator knob casing 217132. Control 217130 additionally comprises a first connected strain gauge circuit a and/or integrated in the first casing portion 217131 and a second strain gauge circuit 217139 connected to and/or integrated into the second casing portion 217133. The first strain gauge circuit 217137 and the second strain gauge circuit 217139 are in signal communication with the engine control system via one or more wires or conductors 217136. first portion of wrap 217131 is configured to deflect and/or deform when a clinician presses on the first portion of wrap 217131 and in such cases the engine control system is configured to detect the change in resistance at the first strain gauge circuit 217137. Similarly, the wall of the second sheath portion 217133 is configured to deflect and/or deform when a physician presses the second sheath portion 217133, and in such cases the engine control system is configured to detect the change in resistance in the second strain gauge circuit 217139. When the engine control system detects an increase in resistance in the first strain gauge circuit 2171 37, the engine control system operates the linkage drive motor to link the end actuator in a first direction.
[0381] [0381] In addition to the above, the 217140 control is also operable to operate the articulation drive motor on the handle
[0382] [0382] In addition to the above, the 217150 control is operable to operate a trigger drive motor on the 217100 handle to perform, for example, a staple firing stroke, a clip crimping stroke, or a needle suture stroke - depending on the type of drive shaft assembly attached to the 217100 handle. Referring to Figure 93, the 217150 control is positioned on the 217400 grip actuator and comprises a push button that includes a button housing 217152. The 217150 control additionally comprises a 217154 strain gauge circuit attached to and/or integrated into the 217152 button housing. The 217154 strain gauge circuit is in signal communication with the engine control system via one or more wires or conductors 217156. The 217152 button cover wall is configured to deflect and/or deform when a clinician presses the 217152 button cover, and in such cases the engine control system is configured o to detect the change in resistance in strain gauge circuit 217154. When the engine control system detects an increase in resistance in strain gauge circuit 217154, the engine control system operates the trigger drive motor to drive a firing member distally. For this purpose, the motor control system is configured to track the position of the trigger member so as to know when the trigger member has reached the end of its trigger stroke and stop the trigger drive motor. In at least one embodiment, the motor control system comprises an encoder, for example, for tracking the position of the firing member. In addition to the above, the motor control system is configured to stop the trigger motor when the clinician releases or withdraws the hand from control 217150. In such cases, similar to the above, the button wrap 217152 returns from resiliently to its original configuration and the resistance in the 217154 strain gauge circuit returns to its original state, which is detected by the engine control system.
[0383] [0383] As discussed above, controls 217130, 217140, and 217150 are deformable to perform a surgical instrument function. When the 217130, 217140, and 217150 controls are readily deformable, they can experience high mechanical stresses that are readily detectable by their respective strain gauge circuits. Referring to Figure 95, an actuator 217170 comprises a button housing 217172 that has one or more live joints 217174 defined in the walls of the button housing 217172. Such live joints 217174 may allow the button housing 217172 to deform. promptly. Button wrap punctuation marks 217172 can also be used. In many cases, an actuator may comprise a feature that causes the actuator housing to suddenly flex, snap-fit elastically, or buckle when a force limit is exceeded. That said, such readily deformable controls can be accidentally actuated by the clinician. For this purpose, the motor control system may utilize one or more measured stress limits that may reduce the possibility that the surgical instrument will respond to incidental touches from controls 217130, 217140, and 217150. For example, for mechanical stresses measured by the circuit strain gauge 217144 of actuator 217140 that are below a threshold, the system
[0384] [0384] Referring to Figure 94, in addition to the above, an actuator 217160 comprises a solid button housing 217162. Unlike the button housing 217172, the button housing 217162 is configured such that it does not deform. significantly when it is acted upon. As a result, the motor control system in communication with the 217160 actuator strain gauge circuit is configured to be responsive to much lower measured stress values. On the other hand, the 217160 actuator can be used to perform an important function of the surgical instrument and it may be desirable to have a high measured stress limit to prevent accidental actuation of the important function despite having a rigid actuator button wall.
[0385] [0385] When an actuator is easily deformable, in addition to the above, the clinician would need to promptly detect that it has triggered the actuator when the actuator wall yields or retracts elastically. When an actuator is rigid, however, a clinician may not be able to intuitively detect that the actuator has been actuated. In any case, a surgical instrument may include a tactile feedback generator in communication with the engine control system. When the engine control system determines that the measured effort in an actuator strain gauge circuit has exceeded a predetermined threshold, the engine control system can activate the tactile feedback generator that can notify the clinician that the actuator has has been sufficiently activated. In many cases, the tactile generator comprises at least one visual indicating device, such as a lamp, for example, at least one auditory indicating device, such as a loudspeaker, for example, and/or at least one vibrating indicating device, like an electric motor with an eccentric rotating element, for example.
[0386] [0386] In various embodiments, in addition to the above, a motor control system may utilize two or more measured stress limits in connection with an actuator, such as the 217160 actuator, for example, to determine proper surgical instrument action. For example, the engine control system may comprise a first measured stress limit and a second measured stress limit that is higher than the first stress limit. When the measured effort is below the first measured effort limit and the second measured effort limit, the engine control system will not drive the electric motor of the drive system associated with the actuator. When the measured effort is at or above the first measured effort limit but below the second measured effort limit, the engine control system triggers a first tactile feedback generator, such as a first light, but does not start the engine. electric. When the measured effort is at or above the second measured effort limit, the engine control system triggers a second tactile feedback generator, such as a first light, and drives the electric motor. In such cases, the clinician receives a warning or notification through the first tactile feedback generator that he is pressing the actuator in some way, intentionally or not. When the measured effort drops below the second measured effort limit but not the first measured effort limit, the engine control system disables the second tactile feedback generator but not the first tactile feedback generator. The engine control system also suspends the electric motor in these cases. When the measured effort drops below the first measured effort threshold, the engine control system deactivates the first tactile feedback generator.
[0387] [0387] In addition to the above, actuators 217130 and 217140 are comprised of a different material than the 217110 handle housing. The 217130 and 217140 actuators are comprised of a first plastic material and the 217110 handle housing is comprised of of a second plastic material which is different from the first plastic material. The first plastic material is more flexible than the second plastic material so the actuators can be deformed to activate the surgical instrument as described above. In several cases, the first plastics material is selected so that the elastic modulus of the first plastics material is lower than the elastic modulus of the second plastics material. In any case, the 217130 and 217140 actuators are manufactured separately from the 217110 handle housing and then mounted in the 217110 handle housing. The 217130 and 217140 actuators and the 217110 handle housing comprise cooperating features that interlock with each other. to connect the 217130 and 217140 actuators to the 217110 handle housing. In at least one embodiment, the 217130 and 217140 actuators are placed in a mold and the 217110 handle housing is injection molded around the 217130 and 217140 actuators so that the button cabinets are kept in place, but sufficiently exposed for the clinician to be able to operate them. Similar to the above, the interlocking features between the 217130 and
[0388] [0388] In several alternative embodiments, in addition to the above, the 217130 and 217140 actuators are comprised of the same material as the 217110 handle housing. In at least one such embodiment, the 217130 and 217140 actuators are thinner than the handle housing. 217110 grip so that they can deform sufficiently to actuate the surgical instrument while the 217110 grip housing is rigid enough not to deform unacceptably during use. Similar to the above, the 217130 and 217140 actuators can be manufactured separately from the 217110 Handle Enclosure and then mounted in the 217110 Handle Enclosure. In at least one alternative embodiment, the 217130 and 217140 Actuators are integrally formed with the 217110 Handle Enclosure. 217110. In such cases, the 217110 grip housing can be formed into two halves that are fitted together by a snap-fit connection, fasteners, and/or one or more adhesives, for example. In at least one embodiment, the 217130 and 217140 actuators and the 217110 grip housing are formed during an injection molding process. In such cases, strain gauge circuits 217134 and 217144 can be positioned in the mold before the molten plastic is injected into the mold so that strain gauge circuits 217134 and 217144 are at least partially integrated into actuators 217130 and 217140. Otherwise , strain gauge circuits 217134 and 217144 can be applied to actuators 217130 and 217140 respectively after the injection molding process. Similar to the above, the 217130 and 217140 actuators are thinner than the 217110 handle housing so that they can deform sufficiently to actuate the surgical instrument while the 217110 handle housing is rigid enough not to deform unacceptably during operation. use. Such arrangements can eliminate the junctions between the 217130 and 217140 actuators and the 217110 Handle Enclosure and create a sealed interface between the 217130 and 217140 Actuators and the 217110 Handle Enclosure. The discussion provided above also applies to the 217400 Closing Actuator. and the 217150 actuator which, once manufactured, can be mounted in the 217110 grip housing.
[0389] [0389] In many cases, the plastics used to form the 217130 and 217140 actuators and/or the 217110 grip housing are capable of being galvanized. In at least one of these cases, the conductive tracks are galvanized directly on the 217130 and 217140 actuators and/or the 217110 handle housing. The galvanized conductive tracks can be made of any suitable material, such as tin and/or silver, for example. .
[0390] [0390] In various embodiments, sensors and/or switches other than strain gauges can be used to actuate the electric motors of an engine control system. In at least one such embodiment, a handle and/or drive shaft of a surgical instrument comprises at least one actuator that is deflectable to contact a sensor and/or switch to open and/or close a circuit. sensor, as the case may be, to actuate an electric motor of the surgical instrument. Similar to the above, such an actuator may comprise a separate component which is mounted in the grip housing, for example, and which is deformable inwardly to contact a sensor and/or switch. Also similar to the above, such an actuator may comprise a thin integral portion of the grip housing which is inwardly deformable to contact a sensor and/or switch. In either case, the sensor and/or switch is positioned behind and aligned with the actuator and can be mounted on a circuit board, for example.
[0391] [0391] Again referring to Figure 82, the 215500 drive shaft assembly comprises actuators 215520, 215530 and 215540 that are configured to operate in the same or similar manner as the other actuators described herein. The 215500 drive shaft assembly actuators comprise slide rail actuators, radial actuators, rotary actuators, push button actuators, and/or any other suitable actuators. In many cases, the 215500 Drive Shaft Assembly is not intended to be reused after the surgical procedure and is therefore disposable. In certain cases, the 215500 Drive Shaft Assembly can be reused if it has not exceeded its maximum allowable number of actuations and has been sanitized and re-sterilized. The 215100 grip can also be disposable or reusable.
[0392] [0392] In several alternative embodiments, an actuator can be actuated without having to be deflected and/or deformed. In at least one such embodiment, the actuator comprises a capacitive sensor circuit attached to and/or integrated within the housing of the handle which is in signal communication with the motor control system. The capacitive sensor circuit comprises one or more capacitive sensors that are evaluated by the motor control system for changes in its capacitance when the physician places his finger on and/or on one of the capacitive sensors. When the measured capacitance, or capacitance change, exceeds a predetermined threshold, the motor control system drives the electric motor of the drive system associated with the actuator. When the measured capacitance, or capacitance change, falls below the predetermined threshold, the motor control system no longer drives the electric motor. That said, the motor control system can be configured to take any appropriate action when the measured capacitance, or capacitance change, drops below a predetermined threshold.
[0393] [0393] In at least one case, in addition to the above, the handle housing comprises recesses defined in it and the capacitive sensors are positioned in the recesses. Such an arrangement makes it possible for capacitive sensors to be flush, or at least substantially flush, with the outer surface of the grip housing. In at least one of these cases, the capacitive sensors may have a different color than the grip housing so that they are readily observable by the clinician.
[0394] [0394] In several cases, in addition to the above, an actuator comprises a membrane switch. In at least one case, a membrane switch comprises two conductive plates separated by dielectric points positioned between the conductive plates. One or both of the conductive plates are configured to flex when the membrane switch is pressed and change the electrical state of the membrane switch. The membrane switch may be hermetically sealed to prevent water and/or contaminants from entering the membrane switch which could unintentionally alter the electrical properties of the membrane switch.
[0395] [0395] In addition to the above, an actuator may comprise a piezoelectric sensor circuit attached to and/or embedded within the grip housing that is in signal communication with the motor control system. The piezoelectric sensor circuit comprises one or more piezoelectric sensors that are evaluated by the motor control system for changes in the motor's electrical properties when the physician places his finger on and/or on one of the capacitive sensors. When the measured electrical property, or the change in electrical property, exceeds a predetermined threshold, the motor control system drives the electric motor of the drive system associated with the actuator. When the measured electrical property, or the change in electrical property, drops below the predetermined threshold, the motor control system no longer drives the electric motor. That said, the engine control system can be configured to take any appropriate action when the measured electrical property, or electrical property change, falls below a predetermined threshold. In at least one case, the handle housing comprises recesses defined in it and the capacitive sensors are positioned in the recesses. Such an arrangement makes it possible for piezoelectric sensors to be flush, or at least substantially flush, with the outer surface of the grip housing. In at least one of these cases, the piezoelectric sensors may have a different color than the handle housing so that they are readily observable by the clinician.
[0396] [0396] Referring to Figure 96, a 218100 handle comprises a 218110 handle housing, a 218140 push-button actuator, a 218400 rotary actuator, and a 218800 positionable actuator. swivel to the 218110 grip housing around a 218820 pivot pin that defines an axis of rotation RA. The 218820 pivot pin is secured to the 218110 cabinet so that the 218800 positionable actuator does not translate, or at least substantially translates, with respect to the 218110 cabinet. In addition, the 218820 pivot pin fits snugly into an opening in the cabinet. 218110 so that rotating the arm 218810 about the geometric axis of rotation RA requires a concerted effort on the part of the clinician. In at least one instance, pivot pin 218820 comprises a locking screw that is loosenable to pivot arm 218810 and tightenable to lock arm 218810 in position. In either case, the 218810 arm can be pivoted into a comfortable position for the clinician so that a 218830 joystick on the 218810 arm is easily accessible by the clinician. The 218830 joystick comprises one or more sensors communicating with the 218100 handle's motor control system. In use, the motor control system is configured to interpret and utilize voltages, currents, and/or any other data. 218830 joystick sensors to pivot the end actuator of a drive shaft assembly attached to the 218100 handle. The end actuator is pivotable in more than one plane and can pivot around one or more pivot joints by one or more motor driven linkage drive systems.
[0397] [0397] Referring to Figure 97, a handle 218100' comprises a handle housing 218110', a push-button actuator 218140, a rotary actuator 218400 and a positionable actuator 218800'. The positionable actuator 218800' comprises an arm 218810' which is pivotally mounted to the grip housing 218110' around a pivot pin 218820' which defines a geometric axis of rotation RA. Pivot pin 218820' is secured to cabinet 218110' so that positionable actuator 218800' does not translate, or at least substantially translates, with respect to cabinet 218110'. In addition, pivot pin 218820' fits snugly into an opening in cabinet 218110' so that rotation of arm 218810' about the axis of rotation RA requires a concerted effort on the part of the clinician. In at least one case, pivot pin 218820'
[0398] [0398] Referring to Figure 98, a 219100 surgical instrument handle comprises a 219110 handle housing, a 218140 button actuator, and a 219130 joystick. Unlike the 218130 joystick, the 219130 joystick is not mounted on an arm. The 219830 joystick comprises one or more sensors in communication with the 219100 grip motor control system. In use, the motor control system is configured - Used to interpret and use voltages, currents, and/or any other data from the 219830 joystick sensors to pivot the end actuator of a drive shaft assembly attached to the 219100 handle. The end actuator is pivotable in more than one plane and may be articulated around one or more swivel joints by one or more motor-driven articulation drive systems.
[0399] [0399] In addition to or in place of a joystick to control the end actuator joint, a surgical instrument may include a projected capacitive touchscreen (PCAP = "projected capacitive touchscreen") designed to control the end actuator linkage.
[0400] [0400] In addition to the above, the PCAP touchscreen may include icons on it that facilitate the use of the PCAP touchscreen and suggest how finger movements will be interpreted by the microprocessor. A finger tap icon is shown in Figure 99. A finger drag icon is shown in Figure 100. A rotating finger swipe is shown in Figure 101. Such icons could also be positioned in the grip housing. .
[0401] [0401] An operating room is often divided into a sterile field and a non-sterile field. During a surgical procedure, certain physicians remain in the sterile field while other physicians remain in the non-sterile field. Typically, surgical instruments within the sterile field are handled by physicians in the sterile field. That said, cases are foreseen in which a surgical instrument comprises a sterile barrier that allows a physician, in the sterile field or in the non-sterile field, to interact with the surgical instrument. In at least one case, the sterile barrier comprises a flexible membrane mounted on the surgical instrument. Depending on the surgical instrument and its use, the entire surgical instrument or only a portion of the surgical instrument is protected by the sterile barrier. In at least one instance, the surgical instrument comprises one or more pressure-sensitive screens that can be worn across the sterile barrier. In use, the surgical instrument in the sterile barrier can generate heat. For this purpose, the sterile barrier may comprise a heat sink configured to extract heat from within the sterile barrier and dissipate the heat to the surrounding environment. The heat sink can be comprised of any suitable thermally conductive material, such as copper and/or silver, for example. Silver offers an added advantage due to its antimicrobial properties. In at least one case, the heat sink comprises a set of conductive tracks that extend within the sterile barrier. Conductive tracks are integrated, affixed, and/or printed on the sterile barrier. These tracks can promote heat transfer by conduction. In at least one case, the conductive tracks comprise fins that extend from the sterile barrier. These fins can promote convection heat transfer. In several cases, the materials of the sterile barrier and/or the conductive tracks are comprised of a material that promotes heat transfer by radiation.
[0402] [0402] As discussed above, a surgical instrument may comprise two or more circuit boards that are operatively interconnected by one or more electrical connectors. In many cases, an electrical connection comprises two halves - a male half connection and a female half connection. The male connection half comprises male electrical contacts which may comprise pins, for example, while the female connection comprises female electrical contacts which may comprise sockets, for example, configured to receive the pins.
[0403] [0403] In view of the above, a control circuit of a surgical instrument comprising one or more electrical interconnections can be configured to assess the contact quality of the electrical interconnections after the surgical instrument components have been assembled together and/or during use of the surgical instrument. The control circuit is configured to assess whether the signal across an electrical connection is being distorted by the electrical connection. In at least one case, the control circuit comprises a signal emitter configured to send a signal through an electrical circuit including an electrical contact, a signal receiver configured to compare the return signal with the expected return signal, and a digital signal processor to determine if there is signal distortion. Any suitable algorithm can be used to evaluate signal distortion, such as an algorithm that uses the root mean square of the signal, for example. If the return signal for each of the electrical circuits sufficiently matches their expected return signal, then the control circuit can communicate to the user of the surgical instrument that the fidelity of the signal within the surgical instrument is sufficient. In at least one case, the control circuit comprises an indicator light, such as an LED, for example, which lights up to indicate that there is sufficient signal fidelity in the surgical instrument. If one or more of the return signals does not sufficiently match its expected return signal, the control circuit may communicate to the surgical instrument user that the signal fidelity within the surgical instrument may not be sufficient. In such cases, another LED could light up and/or the signal fidelity LED could comprise a two-color LED that can be switched from green to red, for example. In many cases, the control circuit is configured to use more than one signal fidelity threshold - a first threshold above which there is sufficient signal fidelity (or an acceptable amount of noise), a second threshold below the first threshold. above which indicates the possibility that there is possibly sufficient signal fidelity (or a potentially inadequate amount of noise), and a third threshold below the second threshold below which indicates that there is insufficient signal fidelity (or extensive noise) . When the fidelity signal of an electrical circuit is between the first and second limits, the control circuit can increase the gain of the power supplied to that circuit to improve the fidelity of the signal. In at least one case, the voltage magnitude is increased. In certain cases, the control circuit may adjust the communication speed through an electrical circuit in view of the signal-to-noise ratio. For high signal-to-noise ratios, the control circuit can transmit data through the electrical contact interface at a high speed or with short intervals between data, or data packets, for example. For low signal-to-noise ratios, the control circuit can transmit data through the electrical contact interface at a lower speed or with longer intervals between data, or data packets, for example.
[0404] [0404] In addition to or in lieu of the above, a control circuit is configured to evaluate the voltage drop across an electrical contact interface. For example, when the control circuit detects that a lower than expected voltage potential is being applied to an electronic device within an electrical circuit, the control circuit may increase the gain of the power supplied to that electrical circuit. In at least one of these cases, the voltage magnitude is increased, for example. When a short circuit is detected in an electrical circuit, the surgical instrument may become totally unusable or limited in the functions it can perform. For this purpose, the control circuit, a processing circuit and/or an algorithm can be used to decide whether or not the short circuit is present in a critical function, if the surgical instrument can still be used, and which functions are still available. can be used. Upon detecting a short circuit, in many cases, the control circuit may enter a slow operating mode that only allows the execution of surgical instrument functions that allow the removal of the surgical instrument from the patient and/or allow the surgical instrument to be removed from the patient. the state of the surgical instrument is monitored by the doctor, for example. In addition to or in lieu of the above, the control circuit may run an algorithm to assess whether a detected short circuit is, in fact, a short circuit. In at least one case, the algorithm operates to increase the gain of the signal in the electrical circuit by detecting a short circuit and, if the short circuit is still detected after increasing the gain, the circuit of control quickly interrupts power to the electrical circuit comprising the short circuit. However, if the increase in signal gain establishes or re-establishes sufficient signal fidelity, then the control circuit can continue to support the use of that electrical circuit.
[0405] [0405] In addition to the above, signal fidelity and/or voltage drop in an electrical circuit can be evaluated when surgical instrument components are assembled. Electrical circuits can also be evaluated when the surgical instrument is energized and/or activated from a low-power or suspend mode. Electrical circuits can be evaluated intermittently or continuously during the entire operation of the surgical instrument. In many cases, the control circuit of a surgical instrument may enter a slow operating mode when signal distortion and/or voltage drop exceeds a predetermined threshold. In many cases, the control circuit may enter a slow operating mode that only allows the execution of surgical instrument functions that allow the removal of the surgical instrument from the patient and/or that allow the status of the surgical instrument to be monitored by the physician. , for example. The control circuit may also attempt to correct for signal distortion and/or voltage drop by increasing signal gain, for example. When fluid enters an electrical interface, however, increasing the signal gain may not resolve these issues.
[0406] [0406] In various cases, in addition to the above, the surgical instrument may comprise a fan positioned to blow air across the electrical interface when signal distortion and/or voltage drop in one or more electrical circuits is high, or is above a predetermined threshold. In many cases, the fan forms a part of the control circuit. In at least one case, the ventilator is placed proximal to the electrical interface so that air is blown in a proximal to distal direction, for example. In certain cases, the surgical instrument can be configured to at least partially inflate the patient with carbon dioxide, for example. In such cases, the insufflation path may pass over the electrical interface which can dry out the electrical interface and/or prevent entry from in the first place. The control circuit comprises a speed control circuit, such as a pulse width modulation (PWM) circuit, a frequency modulation (FM) circuit, and/or a variable resistance circuit, for example, configured to operate the fan at different speeds. In such cases, the control circuit is configured to run the fan at a higher speed when signal distortion and/or voltage drop is higher and at a lower speed when signal distortion and/or voltage drop is higher. voltage is lower. In various cases, the patient may also be inflated through one or more trocars, or ports, which extend into the patient. In these cases, the control circuit is configured to communicate with a central surgical controller system when the ventilator is turned on, off, accelerated, and/or decelerated, so that the insufflation amounts can be properly controlled by the ventilator. central surgical controller system. When too much supply gas is being supplied to the patient by an inflation system and/or a surgical instrument, and/or when the amount of supply gas being supplied to the patient is increased too much, the central surgical controller system may operate to reduce the amount of insufflation gas being insufflated to the patient through the insufflation trocar. When the amount of supply gas being supplied to the patient through the surgical instrument is too low, the central surgical controller system can operate to increase the amount of supply gas being supplied to the patient through the trocar. of insufflation.
[0407] [0407] In addition to or in lieu of the above, the surgical instrument comprises a heating circuit positioned and configured to dry the electrical interface when water ingress into one of the electrical circuits is detected by the control circuit. In at least one of these cases, the heating circuit comprises a resistive heating circuit, for example, which comprises a heating resistor adjacent to the electrical interface. When signal distortion and/or voltage drop exceeds a predetermined threshold, the control circuit can supply the heating circuit and/or increase the current through the heating circuit, for example. When the signal distortion and/or voltage drop drops below a predetermined threshold, the control circuit may turn off the heating circuit immediately, power the heating circuit for an additional predetermined period of time, and/or reduce the current in the heating circuit, for example.
[0408] [0408] As discussed above, a drive shaft assembly can be selectively attachable to a surgical instrument handle. As also discussed above, the drive shaft assembly may comprise a flexible drive shaft circuit and the handle may comprise a flexible handle circuit. In many cases, the flexible drive shaft circuit and the flexible grip circuit comprise electrical connectors that interconnect, or become electrically coupled, when the drive shaft assembly is mounted on the handle of a drive shaft. so that the flexible circuits are placed in electrical communication with each other. One or both of the electrical connectors may comprise a seal that can seal the electrical interconnection when the electrical connectors are mated; however, one or both of the electrical connectors may comprise unsealed electrical contacts or exposed electrical contacts before the interconnection is made. In certain cases, electrical contacts may be exposed to fluids and/or contaminants. An alternative approach is illustrated in Figure 101A which shows a 219220 handle flexible circuit and a 219520 drive shaft flexible circuit. The 219220 handle flexible circuit comprises a flexible substrate and electrical tracks 219230 integrated into the flexible substrate. Similarly, the flexible drive shaft circuit 219520 comprises a flexible substrate and electrical tracks 219530 integrated into the flexible substrate. Referring to Figure 101B, electrical tracks 219230 and 219530 are positioned adjacent to each other when the drive shaft assembly is mounted on the handle and are placed in communication with each other. In such cases, the tracks 219230 and 219530 form a capacitive and/or inductive connection interface and can communicate electrical signals and/or electrical energy through the interface between them. As a result, the overlapping tracks 219230 and 219250 are terminated and/or sealed so that their exposure to fluids and/or contaminants is reduced, or even eliminated. The substrate walls surrounding tracks 219230 and 219530 can be thin, and in many cases tracks 219230 and 219530 can be printed onto their respective substrates to improve the fidelity of interconnection between them.
[0409] [0409] As illustrated in Figures 101A and 101B, tracks 219230 and 219530 comprise spikes that overlap each other when flexible circuits 219220 and 219520 are interconnected. To facilitate this interconnection, the flexible grip circuit 219220 comprises magnets 219240 and the flexible drive shaft circuit 219520 comprises magnets 219540 which are arranged to attract each other when placed in close proximity to each other and place the circuits flexible 219220 and 219520 in contact with each other as illustrated in Figure 101B. The 219240 and 219540 magnets are arranged in two pairs, but can comprise any suitable number and/or arrangement.
[0410] [0410] A control circuit of a surgical instrument may be used to perform variable rate control for a motor-driven system of the surgical instrument. Such motor-driven systems may include, for example, a closing system, a triggering system, and/or a surgical instrument linkage system. In some cases, it is beneficial to use only a hardware-only control circuit implementation to perform variable rate control of the motor-driven system. For example, a hardware-only implementation can be used to provide faster operation than implementations that require software and/or firmware to be run by a processing device. In addition, a hardware-only implementation can be used to eliminate the cost and complexity required by processors, software, and/or firmware. Additionally, a hardware-only implementation can provide greater reliability, greater durability, and an increase in control circuit life. In addition, a hardware-only implementation can also expand the options available for sterilization of the surgical instrument.
[0411] [0411] In many cases, rotation of a knob on a surgical instrument and/or pulling or pushing a surgical instrument input device can cause a proportional change in motor position. In certain cases, a variable pull of a key or other input device of the surgical instrument can cause a proportional speed of advance of the motor.
[0412] [0412] Figure 102 illustrates a 220000 control circuit of a surgical instrument. Control circuit 220000 is shown as a combinational logic circuit and is used to supply input signals and/or waveforms to a motor controller 220002 which controls the rotational speed of a surgical instrument motor. In response to input signals from the 220000 control circuit, the 200002 motor controller operates to change action rates of a device's function based on a parameter that is detected or activated as a result of the function being performed. For example, in various cases, the function of the device may be the articulation of an actuator end of the surgical instrument, the rate of action may be the speed of the articulation in the opposite direction to a longitudinal axis of the drive shaft, and the parameter it can be the position of the end actuator with respect to the longitudinal axis of the drive shaft. In many cases, the parameter that can be detected or activated is the state of an input device, such as a switching device (either open or closed), which can be changed or "touched" by a user of the surgical instrument.
[0413] [0413] In addition to the above, the control circuit 220000 includes a first E port 220004, a monostable multivibrator 220006, an asynchronous counter 220008, a first inverter 220010 (shown as a circle), a second E port 220012, or a 220014 OR port, a 220016 second drive (shown as a circle), and a 220018 third E port. In many cases, the 220000 control circuit also includes the 22002 motor controller.
[0414] [0414] A detection device 220020, which is shown in Figure 102 as a user switch, is connected to a first input terminal 220022 of the first E port 220004 and to an input terminal 220024 of the monostable multivibrator 220006 In many cases, the 220000 control circuit also includes the 220020 detection device, which can be implemented as a switching device, such as a limit switch, a position sensor, a pressure sensor, and/or a sensor. of strength, among others. According to various aspects, the sensing device 220020 can be implemented as an input device, such as a switching device, which can be triggered or "touched" by a user of the surgical instrument.
[0415] [0415] The 220020 detection device is configured to detect a parameter associated with the surgical instrument and emit a signal representative of the detected parameter. For example, according to various aspects, the detected parameter may be a surgical instrument user "pressing" or "touching" the 220020 detection device. According to other aspects, the detected parameter may be the trigger actuator. end passing through a zone defined around a centered state (for example, through a zone defined with respect to the longitudinal geometric axis of the drive shaft). The signal output by the 220020 sensing device can be conditioned as needed (not shown) for input to the 220000 control circuit. According to various aspects, the 220020 sensing device can output a signal that is representative of a logic level. "1" or a "high" signal (e.g. 0.5V) when the end actuator is not in the defined zone around the centered state, and may output a signal that is representative of a logic level "0" " or a "low" signal (eg 0.0V) when the end actuator is in the defined zone around the centered state. It should be understood that the examples of 0.5 V for a logic "1" or a "high" signal and 0.0 V for a logic "0" or a "low" signal are merely examples. Depending on the specific make and model of logic components used in the 220000 control circuit, a voltage other than 0.5 volts may be representative of a logic "1" signal or a "high" signal and a voltage other than 0, 0 volts can be representative of a "0" logic signal or a "low" signal. As described in more detail later in this document, according to various aspects, a plurality of sensing devices 220020 (i.e., two sensing devices, three sensing devices, etc.) can output signals that are for input to the control circuit 220000.
[0416] [0416] The 220006 monostable multivibrator, also known as the "one-shot" includes a resistor 220026 and a capacitor 220028, as shown in Figure 102, a first output terminal 220030 and a second output terminal 220032. The signal

权利要求:
Claims (21)
[1]
1. Surgical instrument, characterized by comprising: an electric motor; and a control circuit comprising; a plurality of logic gates; and a monostable multivibrator connected to a first of the logic gates, in which the control circuit is configured to change a rate of action of a function of the surgical instrument by controlling the rotational speed of the electric motor based on a detected parameter.
[2]
2. Surgical instrument, according to claim 1, characterized in that the plurality of logic gates includes at least one of the following: an AND gate; an OR gate; and an inverter port.
[3]
Surgical instrument according to claim 1, characterized in that the monostable multivibrator comprises a retriggerable monostable multivibrator.
[4]
4. Surgical instrument, according to claim 1, characterized in that the function of the surgical instrument comprises an articulation of an actuator at the end of the surgical instrument.
[5]
5. Surgical instrument according to claim 1, characterized in that the rate of action comprises a speed of a joint of an end actuator in the opposite direction to a longitudinal geometric axis of a driving axis of the surgical instrument.
[6]
A surgical instrument as claimed in claim 5, characterized in that the speed of the joint is reduced as the end actuator passes through a defined zone around a centered state of a surgical instrument drive axis.
[7]
7. Surgical instrument according to claim 1, characterized in that the detected parameter comprises a detected position of an end actuator in relation to a longitudinal geometric axis of a drive axis of the end actuator.
[8]
Surgical instrument according to claim 1, characterized in that the detected parameter comprises a state of a switching device.
[9]
9. Surgical instrument, according to claim 1, characterized in that the control circuit additionally comprises an asynchronous counter connected to the monostable multivibrator.
[10]
10. Surgical instrument, according to claim 9, characterized in that the asynchronous counter comprises a ripple counter.
[11]
11. Surgical instrument, according to claim 1, characterized in that it additionally comprises a detection device connected to the monostable multivibrator.
[12]
12. Surgical instrument, according to claim 1, characterized in that it additionally comprises a motor controller configured to control the rotation speed of the electric motor.
[13]
13. Surgical instrument, characterized in that it comprises: a flexible circuit comprising at least two conductors, in which the flexible circuit is configured to: transfer electrical energy within the flexible circuit; carrying a signal within the flexible circuit; and provide a secondary function.
[14]
14. Surgical instrument according to claim 13,
characterized in that the flexible circuit comprises a multi-layer flexible circuit.
[15]
Surgical instrument according to claim 13, characterized in that the at least two conductors comprise a twisted pair of conductors that overlap at regular intervals.
[16]
16. Surgical instrument according to claim 15, characterized in that the twisted pair of conductors is configured to mitigate interference from an electromagnetic field from an external source.
[17]
Surgical instrument according to claim 13, characterized in that the at least two conductors comprise a first and second plurality of conductors.
[18]
Surgical instrument according to claim 17, characterized in that the flexible circuit additionally comprises an electromagnetic shield surrounding the first and second plurality of conductors.
[19]
19. Surgical instrument according to claim 13, characterized in that the secondary function comprises electromagnetic shielding.
[20]
20. Surgical instrument, according to claim 13, characterized in that the secondary function comprises short-circuit protection.
[21]
Surgical instrument according to claim 13, characterized in that the secondary function comprises contamination detection.

类似技术:

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同族专利:

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公开号 | 公开日

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CN111787867A|2020-10-16|

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EP3505078A2|2019-07-03|

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US20190201025A1|2019-07-04|

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WO2019133362A8|2020-07-16|

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WO2019133362A1|2019-07-04|

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JP2021509335A|2021-03-25|

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EP3505078A3|2019-07-31|

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法律状态:
2021-12-07| B350| Update of information on the portal [chapter 15.35 patent gazette]|

优先权:

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申请号 | 申请日 | 专利标题

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