U.S. patent application number 13/803086 was filed with the patent office on 2014-09-18 for articulatable surgical instrument comprising an articulation lock.
The applicant listed for this patent is Ethicon Endo-Surgery, Inc.. Invention is credited to Wendy A. Kerr, Richard L. Leimbach, Thomas W. Lytle, IV, Brett E. Swensgard.
Application Number | 20140263541 13/803086 |
Document ID | / |
Family ID | 71135547 |
Filed Date | 2014-09-18 |
United States Patent
Application |
20140263541 |
Kind Code |
A1 |
Leimbach; Richard L. ; et
al. |
September 18, 2014 |
ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION
LOCK
Abstract
A surgical instrument can comprise a handle, a shaft extending
from the handle, and an end effector rotatably coupled to the shaft
by an articulation joint. The surgical instrument can further
include an articulation driver configured to rotate the end
effector about the articulation joint and an articulation lock
which can be configured to selectably resist the unintentional
articulation of the end effector. In various circumstances, the
actuation of the articulation driver can unlock the articulation
lock. In certain circumstances, the articulation lock can comprise
a first one-way lock configured to resist the movement of the
articulation driver in a first direction and a second one-way lock
configured to resist the movement of the articulation driver in a
second direction.
Inventors: |
Leimbach; Richard L.;
(Cincinnati, OH) ; Lytle, IV; Thomas W.; (Liberty
Township, OH) ; Kerr; Wendy A.; (Cincinnati, OH)
; Swensgard; Brett E.; (West Chester, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ethicon Endo-Surgery, Inc. |
Cincinnati |
OH |
US |
|
|
Family ID: |
71135547 |
Appl. No.: |
13/803086 |
Filed: |
March 14, 2013 |
Current U.S.
Class: |
227/175.2 |
Current CPC
Class: |
A61B 2018/1455 20130101;
A61B 2017/00393 20130101; A61B 2017/00477 20130101; A61B 2018/00172
20130101; A61B 2090/0814 20160201; A61B 34/76 20160201; A61B
2017/2931 20130101; A61B 17/072 20130101; A61B 2090/0811 20160201;
A61B 2017/00716 20130101; A61B 34/30 20160201; A61B 2017/2913
20130101; A61B 2017/00464 20130101; A61B 2017/07278 20130101; A61B
2018/00297 20130101; A61B 2017/0046 20130101; A61B 2090/067
20160201; A61B 2017/00734 20130101; A61B 2017/2923 20130101; A61B
2017/2927 20130101; A61B 17/064 20130101; A61B 18/1445 20130101;
A61B 2017/00017 20130101; A61B 2017/00119 20130101; A61B 2017/00123
20130101; A61B 2017/00398 20130101; A61B 2017/00473 20130101; A61B
17/068 20130101; A61B 2090/0808 20160201; A61B 2018/00303 20130101;
A61B 17/0686 20130101; A61B 17/07207 20130101; A61B 2090/064
20160201 |
Class at
Publication: |
227/175.2 |
International
Class: |
A61B 17/064 20060101
A61B017/064 |
Claims
1. A shaft assembly attachable to a handle of a surgical
instrument, said shaft assembly comprising: a shaft comprising a
connector portion configured to operably connect said shaft to the
handle; an end effector; an articulation joint connecting said end
effector to said shaft; a firing driver movable relative to said
end effector when a firing motion is applied to said firing driver;
an articulation driver configured to articulate said end effector
about said articulation joint when an articulation motion is
applied to said articulation driver; and an articulation lock
configured to releasably hold said articulation driver in position,
wherein said articulation motion is configured to unlock said
articulation lock.
2. The shaft assembly of claim 1, wherein said firing motion can
generate said articulation motion.
3. The shaft assembly of claim 1, further comprising a staple
cartridge comprising a plurality of staples removably stored
therein.
4. The shaft assembly of claim 1, wherein said articulation lock
comprises: a first one-way lock configured to releasably resist
movement of said articulation driver in a first direction; and a
second one-way lock configured to releasably resist movement of
said articulation driver in a second direction.
5. The shaft assembly of claim 1, wherein an initial movement of
said articulation driver is configured to unlock said articulation
lock and a subsequent movement of said articulation driver is
configured to articulate said end effector.
6. A shaft assembly attachable to a handle of a surgical
instrument, said shaft assembly comprising: a shaft, comprising: a
connector portion configured to operably connect said shaft to the
handle; and a proximal end; an end effector comprising a distal
end; an articulation joint connecting said end effector to said
shaft; a firing driver movable relative to said end effector by a
firing motion; an articulation driver configured to articulate said
end effector about said articulation joint when an articulation
motion is applied to said articulation driver; and an articulation
lock, comprising: a first one-way lock configured to releasably
resist proximal movement of said articulation driver; and a second
one-way lock configured to releasably resist distal movement of
said articulation driver.
7. The shaft assembly of claim 6, wherein said firing motion can
generate said articulation motion.
8. The shaft assembly of claim 6, further comprising a staple
cartridge comprising a plurality of staples removably stored
therein.
9. The shaft assembly of claim 6, wherein movement of said
articulation driver in a proximal direction is configured to unlock
said first one-way lock, and wherein movement of said articulation
driver in a distal direction is configured to unlock said second
one-way lock.
10. The shaft assembly of claim 6, wherein an initial movement of
said articulation driver is configured to unlock said first one-way
lock or said second one-way lock and a subsequent movement of said
articulation driver is configured to articulate said end
effector.
11. A shaft assembly attachable to a handle of a surgical
instrument, said shaft assembly comprising: a shaft, comprising: a
connector portion configured to operably connect said shaft to the
handle; and a proximal end; an end effector comprising a distal
end; an articulation joint connecting said end effector to said
shaft; a firing driver movable relative to said end effector by a
firing motion; an articulation driver system, comprising: a
proximal articulation driver; and a distal articulation driver
operably engaged with said end effector; and an articulation lock
configured to releasably hold said distal articulation driver in
position, wherein the movement of said proximal articulation driver
is configured to unlock said articulation lock and drive said
distal articulation driver.
12. The shaft assembly of claim 11, wherein said firing motion can
generate said articulation motion.
13. The shaft assembly of claim 11, further comprising a staple
cartridge comprising a plurality of staples removably stored
therein.
14. The shaft assembly of claim 11, wherein said articulation lock
can comprise: a first one-way lock configured to releasably resist
proximal movement of said distal articulation driver; and a second
one-way lock configured to releasably resist distal movement of
said distal articulation driver.
15. The shaft assembly of claim 14, wherein movement of said
proximal articulation driver in a proximal direction is configured
to unlock said first one-way lock, and wherein movement of said
proximal articulation driver in a distal direction is configured to
unlock said second one-way lock.
16. A shaft assembly attachable to a handle of a surgical
instrument, said shaft assembly comprising: a shaft, comprising: a
connector portion configured to operably connect said shaft to the
handle; and a proximal end; an end effector comprising a distal
end; an articulation joint connecting said end effector to said
shaft; a firing driver movable relative to said end effector by a
firing motion; and an articulation driver system, comprising: a
first articulation driver; and a second articulation driver
operably engaged with said end effector; and an articulation lock
configured to releasably hold said second articulation driver in
position, wherein an initial movement of said first articulation
driver is configured to unlock said second articulation driver and
a subsequent movement of said first articulation driver is
configured to drive said second articulation driver.
17. The shaft assembly of claim 16, further comprising a staple
cartridge comprising a plurality of staples removably stored
therein.
18. The shaft assembly of claim 16, wherein said articulation lock
can comprise: a first one-way lock configured to releasably resist
movement of said second articulation driver in a first direction;
and a second one-way lock configured to releasably resist movement
of said second articulation driver in a second direction.
19. The shaft assembly of claim 18, wherein movement of said first
articulation driver in said first direction is configured to unlock
said first one-way lock, and wherein movement of said first
articulation driver in a second direction is configured to unlock
said second one-way lock.
20. A surgical instrument, comprising: a handle; a shaft extending
from said handle; an end effector; an articulation joint connecting
said end effector to said shaft; a firing driver movable relative
to said end effector when a firing motion is applied to said firing
driver; an articulation driver configured to articulate said end
effector about said articulation joint when an articulation motion
is applied to said articulation driver; and an articulation lock
configured to releasably hold said articulation driver in position,
wherein said articulation motion is configured to unlock said
articulation lock.
Description
BACKGROUND
[0001] The present invention relates to surgical instruments and,
in various embodiments, to surgical cutting and stapling
instruments and staple cartridges therefor that are designed to cut
and staple tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] The features and advantages of this invention, and the
manner of attaining them, will become more apparent and the
invention itself will be better understood by reference to the
following description of embodiments of the invention taken in
conjunction with the accompanying drawings, wherein:
[0003] FIG. 1 is a perspective view of a surgical instrument
comprising a handle, a shaft, and an articulatable end
effector;
[0004] FIG. 2 is an elevational view of the surgical instrument of
FIG. 1;
[0005] FIG. 3 is a plan view of the surgical instrument of FIG.
1;
[0006] FIG. 4 is a cross-sectional view of the end effector and the
shaft of the surgical instrument of FIG. 1;
[0007] FIG. 5 is a detail view of an articulation joint which
rotatable connects the shaft and the end effector of FIG. 1 which
illustrates the end effector in a neutral, or centered,
position;
[0008] FIG. 6 is a cross-sectional view of an articulation control
of the surgical instrument of FIG. 1 in a neutral, or centered,
position;
[0009] FIG. 7 is an exploded view of the end effector, elongate
shaft, and articulation joint of the surgical instrument of FIG.
1;
[0010] FIG. 8 is a cross-sectional view of the end effector,
elongate shaft, and articulation joint of the surgical instrument
of FIG. 1;
[0011] FIG. 9 is a perspective view of the end effector, elongate
shaft, and articulation joint of the surgical instrument of FIG.
1;
[0012] FIG. 10 depicts the end effector of the surgical instrument
of FIG. 1 articulated about the articulation joint;
[0013] FIG. 11 is a cross-sectional view of the articulation
control of FIG. 6 actuated to move the end effector as shown in
FIG. 12;
[0014] FIG. 12 is a perspective view of a surgical instrument
comprising a handle, a shaft, and an articulatable end
effector;
[0015] FIG. 13 is a side view of the surgical instrument of FIG.
12;
[0016] FIG. 14 is a perspective view of a firing member and a
pinion gear positioned within the handle of FIG. 12;
[0017] FIG. 15 is a perspective view of the firing member and the
pinion gear of FIG. 14 and a gear reducer assembly operably engaged
with the pinion gear;
[0018] FIG. 16 is a perspective view of the handle of FIG. 12 with
portions thereof removed to illustrate the firing member and the
pinion gear of FIG. 14, the gear reducer assembly of FIG. 15, and
an electric motor configured to drive the firing member distally
and/or proximally depending on the direction in which the electric
motor is turned;
[0019] FIG. 17 is a perspective view of a surgical instrument
comprising a handle, a shaft, an end effector, and an articulation
joint connecting the end effector to the shaft illustrated with
portions of the handle removed for the purposes of
illustration;
[0020] FIG. 18 is a cross-sectional view of the surgical instrument
of FIG. 17;
[0021] FIG. 19 is an exploded view of the surgical instrument of
FIG. 17;
[0022] FIG. 20 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrated with the end effector in an open
configuration, the articulation joint in an unlocked configuration,
and an articulation lock actuator of the surgical instrument handle
illustrated in an unlocked configuration;
[0023] FIG. 21 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrating the end effector in an
articulated, open configuration, the articulation joint in an
unlocked configuration, and an articulation driver engaged with a
firing member of the surgical instrument of FIG. 17, wherein the
movement of the firing member can motivate the articulation driver
and articulate the end effector;
[0024] FIG. 22 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrating the end effector in a closed
configuration, the articulation joint in an unlocked configuration,
and an end effector closing drive being actuated to close the end
effector and move the articulation lock actuator into a locked
configuration;
[0025] FIG. 22A is a cross-sectional detail view of the handle of
the surgical instrument of FIG. 17 illustrated in the configuration
described with regard to FIG. 22;
[0026] FIG. 23 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrating the end effector in a closed
configuration and the articulation joint in a locked configuration,
wherein the actuated closing drive prevents the articulation lock
actuator from being moved into its unlocked configuration
illustrated in FIGS. 20-22;
[0027] FIG. 24A is a plan view of the articulation joint of the
surgical instrument of FIG. 17 illustrated in a locked
configuration;
[0028] FIG. 24B is a plan view of the articulation joint of the
surgical instrument of FIG. 17 illustrated in an unlocked
configuration;
[0029] FIG. 25 is a cross-sectional detail view of the handle of
the surgical instrument of FIG. 17 illustrating the articulation
driver disconnected from the firing member by closure drive;
[0030] FIG. 26 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrating the firing member in an at least
partially fired position and the articulation driver disconnected
from the firing member by the closure drive;
[0031] FIG. 27 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrating end effector in a closed
configuration, the articulation joint and the articulation joint
actuator in a locked configuration, and the firing member in a
retracted position;
[0032] FIG. 28 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrating the end effector in an open
configuration, the end effector closing drive in a retracted
position, and the articulation joint in a locked configuration;
[0033] FIG. 29 is a cross-sectional detail view of the surgical
instrument of FIG. 17 illustrating the end effector in an open
configuration and the articulation joint and the articulation joint
actuator in an unlocked configuration wherein the articulation
driver can be reconnected to the firing drive and utilized to
articulate the end effector once again;
[0034] FIG. 30 is an exploded view of a shaft and an end effector
of a surgical instrument including an alternative articulation lock
arrangement;
[0035] FIG. 31 is a cross-sectional elevational view of the end
effector and the shaft of the surgical instrument of FIG. 30
illustrating the end effector in an unlocked configuration;
[0036] FIG. 32 is a cross-sectional elevational view of the end
effector and the shaft of the surgical instrument of FIG. 30
illustrating the end effector in a locked configuration;
[0037] FIG. 33 is an assembly view of one form of surgical system
including a surgical instrument and a plurality of interchangeable
shaft assemblies;
[0038] FIG. 34 is a perspective view of a surgical instrument
handle coupled to an interchangeable shaft assembly;
[0039] FIG. 35 is an exploded perspective view of the surgical
instrument handle of FIG. 34;
[0040] FIG. 36 is a side elevational view of the handle of FIG. 35
with a portion of the handle housing removed;
[0041] FIG. 37 is an exploded perspective view of an
interchangeable shaft assembly;
[0042] FIG. 38 is a side elevational assembly view of a portion of
the handle and interchangeable shaft assembly of FIG. 34
illustrating the alignment of those components prior to being
coupled together and with portions thereof omitted for clarity;
[0043] FIG. 39 is a perspective view of a portion of an
interchangeable shaft assembly prior to attachment to a handle of a
surgical instrument;
[0044] FIG. 40 is a side view of a portion of an interchangeable
shaft assembly coupled to a handle with the lock yoke in a locked
or engaged position with a portion of the frame attachment module
of the handle;
[0045] FIG. 41 is another side view of the interchangeable shaft
assembly and handle of FIG. 40 with the lock yoke in the disengaged
or unlocked position;
[0046] FIG. 42 is a top view of a portion of an interchangeable
shaft assembly and handle prior to being coupled together;
[0047] FIG. 43 is another top view of the interchangeable shaft
assembly and handle of FIG. 42 coupled together;
[0048] FIG. 44 is a side elevational view of an interchangeable
shaft assembly aligned with a surgical instrument handle prior to
being coupled together;
[0049] FIG. 45 is a front perspective view of the interchangeable
shaft assembly and surgical instrument handle of FIG. 44 with
portions thereof removed for clarity;
[0050] FIG. 46 is a side view of a portion of an interchangeable
shaft assembly aligned with a portion of a surgical instrument
handle prior to being coupled together and with portions thereof
omitted for clarity;
[0051] FIG. 47 is another side elevational view of the
interchangeable shaft assembly and handle of FIG. 46 wherein the
shaft assembly is in partial coupling engagement with the
handle;
[0052] FIG. 48 is another side elevational view of the
interchangeable shaft assembly and handle of FIGS. 46 and 47 after
being coupled together;
[0053] FIG. 49 is another side elevational view of a portion of an
interchangeable shaft assembly aligned with a portion of handle
prior to commencing the coupling process;
[0054] FIG. 50 is a top view of a portion of another
interchangeable shaft assembly and a portion of another surgical
instrument frame arrangement;
[0055] FIG. 51 is another top view of the interchangeable shaft
assembly and frame portion of FIG. 50 after being coupled
together;
[0056] FIG. 52 is an exploded perspective view of the
interchangeable shaft assembly and frame portion of FIG. 50;
[0057] FIG. 53 is another exploded perspective view of the
interchangeable shaft assembly and frame portion of FIG. 52 with
the shaft attachment module of the shaft assembly in alignment with
the frame attachment module of the frame portion prior to
coupling;
[0058] FIG. 54 is a side elevational view of the interchangeable
shaft assembly and frame portion of FIG. 52;
[0059] FIG. 55 is a perspective view of the interchangeable shaft
assembly and frame portion of FIGS. 53 and 54 after being coupled
together;
[0060] FIG. 56 is a side elevational view of the interchangeable
shaft assembly and frame portion of FIG. 55;
[0061] FIG. 57 is another perspective view of the interchangeable
shaft assembly and frame portion of FIGS. 55 and 56 with portions
thereof omitted for clarity;
[0062] FIG. 58 is a top view of a portion of another
interchangeable shaft assembly and frame portion of a surgical
instrument prior to being coupled together;
[0063] FIG. 59 is another top view of the interchangeable shaft
assembly and frame portion of FIG. 58 after being coupled
together;
[0064] FIG. 60 is a perspective view of the interchangeable shaft
assembly and frame of FIGS. 58 and 59 prior to being coupled
together;
[0065] FIG. 61 is another perspective view of the interchangeable
shaft assembly and frame portion of FIGS. 58-60 after being coupled
together;
[0066] FIG. 62 is another perspective view of the interchangeable
shaft assembly and frame portion of FIGS. 58-60 after being coupled
together, with portions of the shaft assembly shown in
cross-section;
[0067] FIG. 63 is an exploded perspective assembly view of another
end effector shaft assembly and frame portion of a surgical
instrument;
[0068] FIG. 64 is a top exploded assembly view of the end effector
shaft assembly and frame portion of FIG. 63;
[0069] FIG. 65 is another exploded perspective assembly view of the
end effector shaft assembly and frame portion of FIGS. 63 and
64;
[0070] FIG. 66 is a perspective view of the end effector shaft
assembly and frame portion of FIGS. 63-65 after being coupled
together;
[0071] FIG. 67 is a side elevational view of the end effector shaft
assembly and frame portion of FIG. 66 with portions thereof omitted
for clarity;
[0072] FIG. 68 is a top exploded assembly view of another end
effector shaft assembly and frame portion of another surgical
instrument;
[0073] FIG. 69 is a perspective exploded assembly view of the end
effector shaft assembly and frame portion of FIG. 68;
[0074] FIG. 70 is another perspective assembly view of the end
effector shaft assembly and frame portion of FIGS. 68 and 69 with
the end effector shaft assembly prior to being latched in coupled
engagement with the frame portion;
[0075] FIG. 71 is a top view of the end effector shaft assembly and
frame portion of FIG. 70;
[0076] FIG. 72 is a top view of the end effector shaft assembly and
frame portion of FIGS. 68-71 after being coupled together;
[0077] FIG. 73 is a side elevational view of the end effector shaft
assembly and frame portion of FIG. 72;
[0078] FIG. 74 is a perspective view of the end effector shaft
assembly and frame portion of FIGS. 72 and 73;
[0079] FIG. 75 is an exploded assembly view of an interchangeable
shaft assembly and corresponding handle with some components
thereof shown in cross-section;
[0080] FIG. 76 is a partial cross-sectional perspective view of
portions of the end effector shaft assembly and the handle of FIG.
75;
[0081] FIG. 77 is a partial perspective view of the end effector
shaft assembly and handle of FIGS. 75 and 76 coupled together with
various components omitted for clarity;
[0082] FIG. 78 is a side elevational view of the end effector shaft
assembly and handle of FIG. 77;
[0083] FIG. 79 is a side elevational view of the end effector shaft
assembly and handle of FIGS. 75-78 coupled together with the
closure drive in an unactuated position and with some components
shown in cross-section;
[0084] FIG. 80 is another side elevational view of the end effector
shaft assembly and handle of FIG. 79 with the closure drive in a
fully actuated position;
[0085] FIG. 81 is an exploded assembly view of an interchangeable
shaft assembly and corresponding handle with some components
thereof omitted for clarity and wherein the closure drive system is
in a locked orientation;
[0086] FIG. 82 is a side view of the end effector shaft assembly
and handle of FIG. 81 coupled together with various components
omitted for clarity and wherein the closure drive system is in an
unlocked and unactuated position;
[0087] FIG. 83 is a side view of the end effector shaft assembly
and handle of FIG. 82 with various components shown in
cross-section for clarity;
[0088] FIG. 84 is a side view of the end effector shaft assembly
and handle of FIGS. 81-83 coupled together with various components
omitted for clarity and wherein the closure drive system is in an
actuated position;
[0089] FIG. 85 is a side view of the end effector shaft assembly
and handle of FIG. 84 with various components shown in
cross-section for clarity;
[0090] FIG. 86 is an exploded perspective assembly view of a
portion of an interchangeable shaft assembly and a portion of a
handle of a surgical instrument;
[0091] FIG. 87 is a side elevational view of the portions of the
interchangeable shaft assembly and handle of FIG. 86;
[0092] FIG. 88 is another exploded perspective assembly view of
portions of the interchangeable shaft assembly and handle of FIGS.
86 and 87 with portions of the interchangeable shaft assembly shown
in cross-section for clarity;
[0093] FIG. 89 is another side elevational view of portions of the
interchangeable shaft assembly and handle of FIGS. 86-88 with
portions thereof shown in cross-section for clarity;
[0094] FIG. 90 is a side elevational view of the portions of the
interchangeable shaft assembly and handle of FIGS. 86-89 after the
interchangeable shaft assembly has been operably coupled to the
handle and with portions of thereof shown in cross-section for
clarity;
[0095] FIG. 91 is another side elevational view of portions of the
interchangeable shaft assembly and handle coupled thereto with the
closure drive system in a fully-actuated position;
[0096] FIG. 92 is an exploded perspective assembly view of a
portion of another interchangeable shaft assembly and a portion of
a handle of another surgical instrument;
[0097] FIG. 93 is a side elevational view of portions of the
interchangeable shaft assembly and handle of FIG. 92 in alignment
prior to being coupled together;
[0098] FIG. 94 is another exploded perspective view of the
interchangeable shaft assembly and handle of FIGS. 92 and 93 with
some portions thereof shown in cross-section;
[0099] FIG. 95 is another perspective view of the interchangeable
shaft assembly and handle of FIGS. 92-94 coupled together in
operable engagement;
[0100] FIG. 96 is a side elevational view of the interchangeable
shaft assembly and handle of FIG. 95;
[0101] FIG. 97 is another side elevational view of the
interchangeable shaft assembly and handle of FIG. 96 with some
components thereof shown in cross-section;
[0102] FIG. 98 is another side elevational view of the
interchangeable shaft assembly and handle of FIGS. 92-96 with the
closure trigger in a fully actuated position;
[0103] FIG. 99 is a perspective view of a portion of another
interchangeable shaft assembly that includes a shaft locking
assembly arrangement;
[0104] FIG. 100 is a perspective view of the shaft locking assembly
arrangement depicted in FIG. 99 in a locked position with the
intermediate firing shaft portion of the firing member of an
interchangeable shaft assembly;
[0105] FIG. 101 is another perspective view of the shaft locking
assembly and intermediate firing member portion with the shaft
locking assembly in an unlocked position;
[0106] FIG. 102 is a schematic illustrating, one, a clutch assembly
for operably connecting an articulation drive to a firing drive of
a surgical instrument and, two, an articulation lock configured to
releasably hold the articulation drive, and an end effector of the
surgical instrument, in position, wherein FIG. 102 illustrates the
clutch assembly in an engaged position and the articulation lock in
a locked condition;
[0107] FIG. 103 is a schematic illustrating the clutch assembly of
FIG. 102 in its engaged position and the articulation lock of FIG.
102 in a first unlocked condition which permits the articulation of
the end effector of FIG. 102 in a first direction;
[0108] FIG. 104 is a schematic illustrating the clutch assembly of
FIG. 102 in its engaged position and the articulation lock of FIG.
102 in a second unlocked condition which permits the articulation
of the end effector of FIG. 102 in a second direction;
[0109] FIG. 104A is an exploded view of the clutch assembly and the
articulation lock of FIG. 102;
[0110] FIG. 105 is a partial perspective view of a shaft assembly
including the clutch assembly of FIG. 102 in its engaged position
with portions of the shaft assembly removed for the purposes of
illustration;
[0111] FIG. 106 is a partial top plan view of the shaft assembly of
FIG. 105 illustrating the clutch assembly of FIG. 102 in its
engaged position;
[0112] FIG. 107 is a partial bottom plan view of the shaft assembly
of FIG. 105 illustrating the clutch assembly of FIG. 102 in its
engaged position;
[0113] FIG. 108 is a partial perspective view of the shaft assembly
of FIG. 105 illustrating the clutch assembly of FIG. 102 in its
engaged position with additional portions removed for the purposes
of illustration;
[0114] FIG. 109 is a partial perspective view of the shaft assembly
of FIG. 105 illustrating the clutch assembly of FIG. 102 in a
disengaged position with additional portions removed for the
purposes of illustration;
[0115] FIG. 110 is a partial perspective view of the shaft assembly
of FIG. 105 illustrating the clutch assembly of FIG. 102 moved into
a disengaged position by a closure drive of the shaft assembly;
[0116] FIG. 111 is a partial plan view of the shaft assembly of
FIG. 105 illustrating the clutch assembly of FIG. 102 in its
engaged position with additional portions removed for the purposes
of illustration;
[0117] FIG. 112 is a partial plan view of the shaft assembly of
FIG. 105 illustrating the clutch assembly of FIG. 102 in a
disengaged position with additional portions removed for the
purposes of illustration;
[0118] FIG. 113 is a plan view of an alternative embodiment of an
articulation lock illustrated in a locked condition;
[0119] FIG. 114 is an exploded view of the articulation lock of
FIG. 113;
[0120] FIG. 115 is a cross-sectional view of another alternative
embodiment of an articulation lock illustrated in a locked
condition;
[0121] FIG. 116 is an exploded view of the articulation lock of
FIG. 114;
[0122] FIG. 117 is a perspective view of another alternative
embodiment of an articulation lock illustrated in a locked
condition;
[0123] FIG. 118 is an exploded view of the articulation lock of
FIG. 117;
[0124] FIG. 119 is an elevational view of the articulation lock of
FIG. 117 illustrating the articulation lock illustrated in a locked
condition;
[0125] FIG. 120 is an elevational view of the articulation lock of
FIG. 117 illustrating the articulation lock in a first unlocked
condition to articulate an end effector in a first direction;
[0126] FIG. 121 is an elevational view of the articulation lock of
FIG. 117 illustrating the articulation lock in a second unlocked
condition to articulate an end effector in a second direction;
[0127] FIG. 122 is another exploded view of the articulation lock
of FIG. 117;
[0128] FIG. 123 is a perspective view of a first lock cam of the
articulation lock of FIG. 117;
[0129] FIG. 124 is a perspective view of a second lock cam of the
articulation lock of FIG. 117;
[0130] FIG. 125 is a perspective view of another alternative
embodiment of an articulation lock illustrated in a locked
condition;
[0131] FIG. 126 is an exploded view of the articulation lock of
FIG. 125;
[0132] FIG. 127 is a cross-sectional elevational view of the
articulation lock of FIG. 125 illustrating the articulation lock in
a first unlocked condition for articulating an end effector in a
first direction;
[0133] FIG. 128 is a cross-sectional elevational view of the
articulation lock of FIG. 125 illustrating the articulation lock in
a locked condition;
[0134] FIG. 129 is a cross-sectional elevational view of the
articulation lock of FIG. 125 illustrating the articulation lock in
a second unlocked condition for articulating an end effector in a
second direction;
[0135] FIG. 130 is a cross-sectional elevational view of the
articulation lock of FIG. 125 illustrating the articulation lock in
a locked condition;
[0136] FIG. 131 is a perspective view of a shaft assembly;
[0137] FIG. 132 is an exploded view of the shaft assembly of FIG.
131 illustrating an alternative embodiment of a clutch assembly for
operably connecting an articulation drive with a firing drive of
the shaft assembly;
[0138] FIG. 133 is another exploded view of the shaft assembly of
FIG. 131;
[0139] FIG. 134 is a partial exploded view of the shaft assembly of
FIG. 131 illustrated with portions removed for the purposes of
illustration;
[0140] FIG. 135 is an end view of the shaft assembly of FIG. 131
illustrated with portions removed for the purposes of
illustration;
[0141] FIG. 136 is another end view of the shaft assembly of FIG.
131 illustrated with portions removed for the purposes of
illustration;
[0142] FIG. 137 is a partial cross-sectional elevational view of
the shaft assembly of FIG. 131;
[0143] FIG. 138 is a partial cross-sectional perspective view of
the shaft assembly of FIG. 131;
[0144] FIG. 139 is another partial cross-sectional view of the
shaft assembly of FIG. 131;
[0145] FIG. 140 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in an engaged position and
illustrated with portions removed for the purposes of clarity;
specifically, a clutch actuator is illustrated while a clutch
sleeve, a switch drum, a proximal articulation driver, and a
closure tube are not illustrated;
[0146] FIG. 141 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in an engaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator and the clutch sleeve are
illustrated while the switch drum, the proximal articulation
driver, and the closure tube are not illustrated;
[0147] FIG. 142 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in a disengaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator and the clutch sleeve are
illustrated while the switch drum, the proximal articulation
driver, and the closure tube are not illustrated;
[0148] FIG. 143 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in a disengaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator, the clutch sleeve, and the
closure tube are illustrated while the switch drum and the proximal
articulation driver are not illustrated;
[0149] FIG. 144 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in a disengaged position; the
clutch actuator, the clutch sleeve, the closure tube, the switch
drum, and the proximal articulation driver are illustrated;
[0150] FIG. 145 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in an engaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator, the clutch sleeve, and the
proximal articulation driver are illustrated while the switch drum
and the closure tube are not illustrated;
[0151] FIG. 146 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in an engaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator, the clutch sleeve, the proximal
articulation driver, and closure tube are illustrated while the
switch drum is not illustrated; moreover, the articulation drive
system of the shaft assembly is illustrated in a centered, or
unarticulated, condition;
[0152] FIG. 147 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in an engaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator, the clutch sleeve, and the
proximal articulation driver are illustrated while the switch drum
and the closure tube are not illustrated; moreover, the
articulation drive system of the shaft assembly is illustrated in a
condition in which an end effector of the shaft assembly would be
articulated to the left of a longitudinal axis of the shaft
assembly;
[0153] FIG. 148 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in an engaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator, the clutch sleeve, and the
proximal articulation driver are illustrated while the switch drum
and the closure tube are not illustrated; moreover, the
articulation drive system of the shaft assembly is illustrated in a
condition in which the end effector of the shaft assembly would be
articulated to the right of the longitudinal axis of the shaft
assembly;
[0154] FIG. 149 is a perspective view of the shaft assembly of FIG.
131 illustrating the clutch assembly in an engaged position and
illustrated with portions removed for the purposes of clarity;
specifically, the clutch actuator, the clutch sleeve, the closure
tube, and the proximal articulation driver are illustrated while
the switch drum is not illustrated;
[0155] FIG. 150 is a perspective view of a surgical instrument in
accordance with certain embodiments described herein;
[0156] FIG. 151 is a schematic block diagram of a control system of
a surgical instrument in accordance with certain embodiments
described herein;
[0157] FIG. 152 is a perspective view of an interface of a surgical
instrument in accordance with certain embodiments described
herein;
[0158] FIG. 153 is a top view of the interface of FIG. 152;
[0159] FIG. 154 is a cross-sectional view of the interface of FIG.
152 in an inactive or neutral configuration in accordance with
certain embodiments described herein;
[0160] FIG. 155 is a cross-sectional view of the interface of FIG.
152 activated to articulate an end effector in accordance with
certain embodiments described herein;
[0161] FIG. 156 is a cross-sectional view of the interface of FIG.
152 activated to return an end effector to an articulation home
state position in accordance with certain embodiments described
herein;
[0162] FIG. 157 is a cross-sectional view of an interface similar
to the interface of FIG. 152 in an inactive or neutral
configuration in accordance with certain embodiments described
herein;
[0163] FIG. 158 is a cross-sectional view of the interface of FIG.
152 activated to articulate an end effector in accordance with
certain embodiments described herein;
[0164] FIG. 159 is a cross-sectional view of the interface of FIG.
152 activated to return the end effector to an articulation home
state position in accordance with certain embodiments described
herein;
[0165] FIG. 160 is a schematic block diagram outlining a response
of a controller of the surgical instrument of FIG. 150 to a reset
input signal in accordance with certain embodiments described
herein;
[0166] FIG. 161 is a schematic block diagram outlining a response
of a controller of the surgical instrument of FIG. 150 to a home
state input signal in accordance with certain embodiments described
herein;
[0167] FIG. 162 is a schematic block diagram outlining a response
of a controller of the surgical instrument of FIG. 150 to a home
state input signal in accordance with certain embodiments described
herein;
[0168] FIG. 163 is a schematic block diagram outlining a response
of a controller of the surgical instrument of FIG. 150 to a firing
home state input signal in accordance with certain embodiments
described herein;
[0169] FIG. 164 is side elevational view of a surgical instrument
including a handle separated from a shaft according to various
embodiments described herein;
[0170] FIG. 165 is a side elevational view of a handle portion
including an interlock switch and a shaft portion including a
locking member according to various embodiments described
herein;
[0171] FIG. 166 is a partial cross-sectional view of the surgical
instrument in FIG. 150 illustrating a locking member in the locked
configuration and an open switch according to various embodiments
described herein;
[0172] FIG. 167 is a partial cross-sectional view of the surgical
instrument in FIG. 150 illustrating a locking member in the
unlocked configuration and a s closed switch depressed by the
locking member according to various embodiments described
herein;
[0173] FIG. 167A is a partial cross-sectional view of the surgical
instrument in FIG. 150 illustrating an advanced firing drive
according to various embodiments described herein;
[0174] FIG. 167B is a partial cross-sectional view of the surgical
instrument in FIG. 150 illustrating a firing drive in a retracted
or default position according to various embodiments described
herein;
[0175] FIG. 168 is a schematic block diagram outlining a response
of a controller of the surgical instrument of FIG. 150 to an input
signal in accordance with certain embodiments described herein;
[0176] FIG. 169 is a schematic block diagram outlining a response
of a controller of the surgical instrument of FIG. 150 to an input
signal in accordance with certain embodiments described herein;
[0177] FIG. 170 is a bottom view of an electric motor and a
resonator according to various embodiments of the present
disclosure;
[0178] FIG. 171 is a perspective view of the resonator of FIG.
170;
[0179] FIG. 172 is a bottom view of the resonator of FIG. 170;
[0180] FIG. 173 is a partial perspective view of a handle of a
surgical instrument depicting the electric motor of FIG. 170 and a
resonator positioned within the handle according to various
embodiments of the present disclosure;
[0181] FIG. 174 is a bottom view of the electric motor and the
resonator of FIG. 173;
[0182] FIG. 175 is a perspective view of the resonator of FIG.
173;
[0183] FIG. 176 is a bottom view of the resonator of FIG. 173;
[0184] FIG. 177 is a partial perspective view of the handle of FIG.
173 depicting the electric motor of FIG. 170 and a resonator
positioned within the handle according to various embodiments of
the present disclosure;
[0185] FIG. 178 is a bottom view of the electric motor and the
resonator of FIG. 177;
[0186] FIG. 179 is a first perspective view of the resonator of
FIG. 177;
[0187] FIG. 180 is a second perspective view of the resonator of
FIG. 177;
[0188] FIG. 181 is a perspective view of the handle of FIG. 173,
depicting the electric motor of FIG. 170, a resonator, and a
retaining ring positioned within the handle according to various
embodiments of the present disclosure;
[0189] FIG. 182 is a flowchart of the operation of a surgical
instrument during a surgical procedure according to various
embodiments of the present disclosure;
[0190] FIG. 183 is an exploded perspective view of the surgical
instrument handle of FIG. 34 showing a portion of a sensor
arrangement for an absolute positioning system, according to one
embodiment;
[0191] FIG. 184 is a side elevational view of the handle of FIGS.
34 and 183 with a portion of the handle housing removed showing a
portion of a sensor arrangement for an absolute positioning system,
according to one embodiment;
[0192] FIG. 185 is a schematic diagram of an absolute positioning
system comprising a microcontroller controlled motor drive circuit
arrangement comprising a sensor arrangement, according to one
embodiment;
[0193] FIG. 186 is a detail perspective view of a sensor
arrangement for an absolute positioning system, according to one
embodiment;
[0194] FIG. 187 is an exploded perspective view of the sensor
arrangement for an absolute positioning system showing a control
circuit board assembly and the relative alignment of the elements
of the sensor arrangement, according to one embodiment;
[0195] FIG. 188 is a side perspective view of the sensor
arrangement for an absolute positioning system showing a control
circuit board assembly, according to one embodiment;
[0196] FIG. 189 is a side perspective view of the sensor
arrangement for an absolute positioning system with the control
circuit board assembly removed to show a sensor element holder
assembly, according to one embodiment;
[0197] FIG. 190 is a side perspective view of the sensor
arrangement for an absolute positioning system with the control
circuit board and the sensor element holder assemblies removed to
show the sensor element, according to one embodiment;
[0198] FIG. 191 is a top view of the sensor arrangement for an
absolute positioning system shown in with the control circuit board
removed but the electronic components still visible to show the
relative position between the position sensor and the circuit
components, according to one embodiment;
[0199] FIG. 192 is a schematic diagram of one embodiment of a
position sensor for an absolute positioning system comprising a
magnetic rotary absolute positioning system, according to one
embodiment;
[0200] FIG. 193 illustrates an articulation joint in a straight
position, i.e., at a zero angle relative to the longitudinal
direction, according to one embodiment;
[0201] FIG. 194 illustrates the articulation joint of FIG. 193
articulated in one direction at a first angle defined between a
longitudinal axis L-A and an articulation axis A-A, according to
one embodiment;
[0202] FIG. 195 illustrates the articulation joint of FIG. 193
articulated in another at a second angle defined between the
longitudinal axis L-A and the articulation axis A'-A, according to
one embodiment;
[0203] FIG. 196 illustrates one embodiment of a logic diagram for a
method of compensating for the effect of splay in flexible knife
bands on transection length;
[0204] FIG. 197 is a schematic of a system for powering down an
electrical connector of a surgical instrument handle when a shaft
assembly is not coupled thereto;
[0205] FIG. 198 is a schematic illustrating a system for
controlling the speed of a motor and/or the speed of a driveable
member of a surgical instrument disclosed herein; and
[0206] FIG. 199 is a schematic illustrating another system for
controlling the speed of a motor and/or the speed of a driveable
member of a surgical instrument disclosed herein.
[0207] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplifications set out
herein illustrate certain embodiments of the invention, in one
form, and such exemplifications are not to be construed as limiting
the scope of the invention in any manner.
DETAILED DESCRIPTION
[0208] Applicant of the present application owns the following
patent applications that were filed on Mar. 1, 2013 and which are
each herein incorporated by reference in their respective
entireties: [0209] U.S. patent application Ser. No. 13/782,295,
entitled ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE
PATHWAYS FOR SIGNAL COMMUNICATION; [0210] U.S. patent application
Ser. No. 13/782,323, entitled ROTARY POWERED ARTICULATION JOINTS
FOR SURGICAL INSTRUMENTS; [0211] U.S. patent application Ser. No.
13/782,338, entitled THUMBWHEEL SWITCH ARRANGEMENTS FOR SURGICAL
INSTRUMENTS; [0212] U.S. patent application Ser. No. 13/782,499,
entitled ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY
ARRANGEMENT; [0213] U.S. patent application Ser. No. 13/782,460,
entitled MULTIPLE PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL
INSTRUMENTS; [0214] U.S. patent application Ser. No. 13/782,358,
entitled JOYSTICK SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS;
[0215] U.S. patent application Ser. No. 13/782,481, entitled SENSOR
STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR; [0216]
U.S. patent application Ser. No. 13/782,518, entitled CONTROL
METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS;
[0217] U.S. patent application Ser. No. 13/782,375, entitled ROTARY
POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM; and
[0218] U.S. patent application Ser. No. 13/782,536, entitled
SURGICAL INSTRUMENT SOFT STOP are hereby incorporated by reference
in their entireties.
[0219] Applicant of the present application also owns the following
patent applications that were filed on even date herewith and which
are each herein incorporated by reference in their respective
entireties: [0220] U.S. patent application entitled CONTROL
ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT, Attorney
Docket No. END7261USNP/130029; [0221] U.S. patent application
entitled INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL
INSTRUMENT, Attorney Docket No. END7259USNP/130030; [0222] U.S.
patent application entitled SENSOR ARRANGEMENTS FOR ABSOLUTE
POSITIONING SYSTEM FOR SURGICAL INSTRUMENTS, Attorney Docket No.
END7262USNP/130032; [0223] U.S. patent application entitled
MULTI-FUNCTION MOTOR FOR A SURGICAL INSTRUMENT, Attorney Docket No.
END7257USNP/130033; [0224] U.S. patent application entitled DRIVE
SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS,
Attorney Docket No. END7254USNP/130034; [0225] U.S. patent
application entitled ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE
SURGICAL INSTRUMENTS, Attorney Docket No. END7258USNP/130035;
[0226] U.S. patent application entitled DRIVE TRAIN CONTROL
ARRANGEMENTS FOR MODULAR SURGICAL INSTRUMENTS, Attorney Docket No.
END7255USNP/130036; [0227] U.S. patent application entitled METHOD
AND SYSTEM FOR OPERATING A SURGICAL INSTRUMENT, Attorney Docket No.
END7256USNP/130037; and [0228] U.S. patent application entitled
ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE,
Attorney Docket No. END7263USNP/130079.
[0229] Certain exemplary embodiments will now be described to
provide an overall understanding of the principles of the
structure, function, manufacture, and use of the devices and
methods disclosed herein. One or more examples of these embodiments
are illustrated in the accompanying drawings. Those of ordinary
skill in the art will understand that the devices and methods
specifically described herein and illustrated in the accompanying
drawings are non-limiting exemplary embodiments and that the scope
of the various embodiments of the present invention is defined
solely by the claims. The features illustrated or described in
connection with one exemplary embodiment may be combined with the
features of other embodiments. Such modifications and variations
are intended to be included within the scope of the present
invention.
[0230] Reference throughout the specification to "various
embodiments," "some embodiments," "one embodiment," or "an
embodiment", or the like, means that a particular feature,
structure, or characteristic described in connection with the
embodiment is included in at least one embodiment. Thus,
appearances of the phrases "in various embodiments," "in some
embodiments," "in one embodiment", or "in an embodiment", or the
like, in places throughout the specification are not necessarily
all referring to the same embodiment. Furthermore, the particular
features, structures, or characteristics may be combined in any
suitable manner in one or more embodiments. Thus, the particular
features, structures, or characteristics illustrated or described
in connection with one embodiment may be combined, in whole or in
part, with the features structures, or characteristics of one or
more other embodiments without limitation. Such modifications and
variations are intended to be included within the scope of the
present invention.
[0231] The terms "proximal" and "distal" are used herein with
reference to a clinician manipulating the handle portion of the
surgical instrument. The term "proximal" referring to the portion
closest to the clinician and the term "distal" referring to the
portion located away from the clinician. It will be further
appreciated that, for convenience and clarity, spatial terms such
as "vertical", "horizontal", "up", and "down" may be used herein
with respect to the drawings. However, surgical instruments are
used in many orientations and positions, and these terms are not
intended to be limiting and/or absolute.
[0232] Various exemplary devices and methods are provided for
performing laparoscopic and minimally invasive surgical procedures.
However, the person of ordinary skill in the art will readily
appreciate that the various methods and devices disclosed herein
can be used in numerous surgical procedures and applications
including, for example, in connection with open surgical
procedures. As the present Detailed Description proceeds, those of
ordinary skill in the art will further appreciate that the various
instruments disclosed herein can be inserted into a body in any
way, such as through a natural orifice, through an incision or
puncture hole formed in tissue, etc. The working portions or end
effector portions of the instruments can be inserted directly into
a patient's body or can be inserted through an access device that
has a working channel through which the end effector and elongated
shaft of a surgical instrument can be advanced.
[0233] FIGS. 1-3 illustrate an exemplary surgical instrument 100
which can include a handle 103, a shaft 104 and an articulating end
effector 102 pivotally connected to the shaft 104 at articulation
joint 110. An articulation control 112 is provided to effect
rotation of the end effector 102 about articulation joint 110. The
end effector 102 is shown configured to act as an endocutter for
clamping, severing and stapling tissue, however, it will be
appreciated that various embodiments may include end effectors
configured to act as other surgical devices including, for example,
graspers, cutters, staplers, clip appliers, access devices,
drug/gene therapy delivery devices, ultrasound, RF, and/or laser
energy devices, etc. The handle 103 of the instrument 100 may
include closure trigger 114 and firing trigger 116 for actuating
the end effector 102. It will be appreciated that instruments
having end effectors directed to different surgical tasks may have
different numbers or types of triggers or other suitable controls
for operating an end effector. The end effector 102 is connected to
the handle 103 by shaft 104. A clinician may articulate the end
effector 102 relative to the shaft 104 by utilizing the
articulation control 112, as described in greater detail further
below.
[0234] It should be appreciated that spatial terms such as
vertical, horizontal, right, left etc., are given herein with
reference to the figures assuming that the longitudinal axis of the
surgical instrument 100 is co-axial to the central axis of the
shaft 104, with the triggers 114, 116 extending downwardly at an
acute angle from the bottom of the handle 103. In actual practice,
however, the surgical instrument 100 may be oriented at various
angles and as such these spatial terms are used relative to the
surgical instrument 100 itself. Further, proximal is used to denote
a perspective of a clinician who is behind the handle 103 who
places the end effector 102 distal, or away from him or herself. As
used herein, the phrase, "substantially transverse to the
longitudinal axis" where the "longitudinal axis" is the axis of the
shaft, refers to a direction that is nearly perpendicular to the
longitudinal axis. It will be appreciated, however, that directions
that deviate some from perpendicular to the longitudinal axis are
also substantially transverse to the longitudinal axis.
[0235] Various embodiments disclosed herein are directed to
instruments having an articulation joint driven by bending cables
or bands. FIGS. 4 and 5 show a cross-sectional top view of the
elongate shaft 104 and the end effector 102 including a band 205
that is mechanically coupled to a boss 206 extending from the end
effector 102. The band 205 may include band portions 202 and 204
extending proximally from the boss 206 along the elongate shaft 104
and through the articulation control 112. The band 205 and band
portions 202, 204 can have a fixed length. The band 205 may be
mechanically coupled to the boss 206 as shown using any suitable
fastening method including, for example, glue, welding, etc. In
various embodiments, each band portion 202, 204 may be provided as
a separate band, with each separate band having one end
mechanically coupled to the boss 206 and another end extending
through the shaft 104 and articulation controller 112. The separate
bands may be mechanically coupled to the boss 206 as described
above.
[0236] Further to the above, band portions 202, 204 may extend from
the boss 206, through the articulation joint 110 and along the
shaft 104 to the articulation control 112, shown in FIG. 6. The
articulation control 112 can include an articulation slide 208, a
frame 212 and an enclosure 218. Band portions 202, 204 may pass
through the articulation slide 208 by way of slot 210 or other
aperture, although it will be appreciated that the band portions
202, 204 may be coupled to the slide 208 by any suitable means. The
articulation slide 208 may be one piece, as shown in FIG. 6, or may
include two pieces with an interface between the two pieces
defining the slot 210. In one non-limiting embodiment, the
articulation slide 208 may include multiple slots, for example,
with each slot configured to receive one of the band portions 202,
204. Enclosure 218 may cover the various components of the
articulation control 112 to prevent debris from entering the
articulation control 112.
[0237] Referring again to FIG. 6, the band portions 202, 204 may be
anchored to the frame 212 at connection points 214, 216,
respectively, which are proximally located from the slot 210. It
will be appreciated that band portions 202, 204 may be anchored
anywhere in the instrument 10 located proximally from the slot 210,
including the handle 103. The non-limiting embodiment of FIG. 6
shows that the band portions 202, 204 can comprise a bent
configuration between the connection points 214, 216 and the slot
210 located near the longitudinal axis of the shaft 104. Other
embodiments are envisioned in which the band portions 202, 204 are
straight.
[0238] FIGS. 7-9 show views of the end effector 102 and elongate
shaft 104 of the instrument 100 including the articulation joint
110 shown in FIG. 5. FIG. 7 shows an exploded view of the end
effector 102 and elongate shaft 104 including various internal
components. In at least one embodiment, an end effector frame 150
and shaft frame 154 are configured to be joined at articulation
joint 110. Boss 206 may be integral to the end effector frame 150
with band 205 interfacing the boss 206 as shown. The shaft frame
154 may include a distally directed tang 302 defining an aperture
304. The aperture 304 may be positioned to interface an
articulation pin (not shown) included in end effector frame 150
allowing the end effector frame 150 to pivot relative to the shaft
frame 154, and accordingly, the end effector 102 to pivot relative
to the shaft 104. When assembled, the various components may pivot
about articulation joint 110 at an articulation axis 306 shown in
FIGS. 9 and 10.
[0239] FIG. 7 also shows an anvil 120. In this non-limiting
embodiment, the anvil 120 is coupled to an elongate channel 198.
For example, apertures 199 can be defined in the elongate channel
198 which can receive pins 152 extending from the anvil 120 and
allow the anvil 120 to pivot from an open position to a closed
position relative to the elongate channel 198 and staple cartridge
118. In addition, FIG. 7 shows a firing bar 172, configured to
longitudinally translate through the shaft frame 154, through the
flexible closure and pivoting frame articulation joint 110, and
through a firing slot 176 in the distal frame 150 into the end
effector 102. The firing bar 172 may be constructed from one solid
section, or in various embodiments, may include a laminate material
comprising, for example, a stack of steel plates. It will be
appreciated that a firing bar 172 made from a laminate material may
lower the force required to articulate the end effector 102. In
various embodiments, a spring clip 158 can be mounted in the end
effector frame 150 to bias the firing bar 172 downwardly. Distal
and proximal square apertures 164, 168 formed on top of the end
effector frame 150 may define a clip bar 170 therebetween that
receives a top arm 162 of a clip spring 158 whose lower, distally
extended arm 160 asserts a downward force on a raised portion 174
of the firing bar 172, as discussed below.
[0240] A distally projecting end of the firing bar 172 can be
attached to an E-beam 178 that can, among other things, assist in
spacing the anvil 120 from a staple cartridge 118 positioned in the
elongate channel 198 when the anvil 120 is in a closed position.
The E-beam 178 can also include a sharpened cutting edge 182 which
can be used to sever tissue as the E-beam 178 is advanced distally
by the firing bar 172. In operation, the E-beam 178 can also
actuate, or fire, the staple cartridge 118. The staple cartridge
118 can include a molded cartridge body 194 that holds a plurality
of staples 191 resting upon staple drivers 192 within respective
upwardly open staple cavities 195. A wedge sled 190 is driven
distally by the E-beam 178, sliding upon a cartridge tray 196 that
holds together the various components of the replaceable staple
cartridge 118. The wedge sled 190 upwardly cams the staple drivers
192 to force out the staples 191 into deforming contact with the
anvil 120 while a cutting surface 182 of the E-beam 178 severs
clamped tissue.
[0241] Further to the above, the E-beam 178 can include upper pins
180 which engage the anvil 120 during firing. The E-beam 178 can
further include middle pins 184 and a bottom foot 186 which can
engage various portions of the cartridge body 194, cartridge tray
196 and elongate channel 198. When a staple cartridge 118 is
positioned within the elongate channel 198, a slot 193 defined in
the cartridge body 194 can be aligned with a slot 197 defined in
the cartridge tray 196 and a slot 189 defined in the elongate
channel 198. In use, the E-beam 178 can slide through the aligned
slots 193, 197, and 189 wherein, as indicated in FIG. 7, the bottom
foot 186 of the E-beam 178 can engage a groove running along the
bottom surface of channel 198 along the length of slot 189, the
middle pins 184 can engage the top surfaces of cartridge tray 196
along the length of longitudinal slot 197, and the upper pins 180
can engage the anvil 120. In such circumstances, the E-beam 178 can
space, or limit the relative movement between, the anvil 120 and
the staple cartridge 118 as the firing bar 172 is moved distally to
fire the staples from the staple cartridge 118 and/or incise the
tissue captured between the anvil 120 and the staple cartridge 118.
Thereafter, the firing bar 172 and the E-beam 178 can be retracted
proximally allowing the anvil 120 to be opened to release the two
stapled and severed tissue portions (not shown).
[0242] FIGS. 7-9 also show a double pivot closure sleeve assembly
121 according to various embodiments. With particular reference to
FIG. 7, the double pivot closure sleeve assembly 121 includes a
shaft closure tube section 128 having upper and lower distally
projecting tangs 146, 148. An end effector closure tube section 126
includes a horseshoe aperture 124 and a tab 123 for engaging the
opening tab 122 on the anvil 120. The horseshoe aperture 124 and
tab 123 engage tab 122 when the anvil 120 is opened. The closure
tube section 126 is shown having upper 144 and lower (not visible)
proximally projecting tangs. An upper double pivot link 130
includes upwardly projecting distal and proximal pivot pins 134,
136 that engage respectively an upper distal pin hole 138 in the
upper proximally projecting tang 144 and an upper proximal pin hole
140 in the upper distally projecting tang 146. A lower double pivot
link 132 includes downwardly projecting distal and proximal pivot
pins (not shown in FIG. 7, but see FIG. 8) that engage respectively
a lower distal pin hole in the lower proximally projecting tang and
a lower proximal pin hole 142 in the lower distally projecting tang
148.
[0243] In use, the closure sleeve assembly 121 is translated
distally to close the anvil 120, for example, in response to the
actuation of the closure trigger 114. The anvil 120 is closed by
distally translating the closure tube section 126, and thus the
sleeve assembly 121, causing it to strike a proximal surface on the
anvil 120 located in FIG. 9A to the left of the tab 122. As shown
more clearly in FIGS. 8 and 9, the anvil 120 is opened by
proximally translating the tube section 126, and sleeve assembly
121, causing tab 123 and the horseshoe aperture 124 to contact and
push against the tab 122 to lift the anvil 120. In the anvil-open
position, the double pivot closure sleeve assembly 121 is moved to
its proximal position.
[0244] In operation, the clinician may articulate the end effector
102 of the instrument 100 relative to the shaft 104 about pivot 110
by pushing the control 112 laterally. From the neutral position,
the clinician may articulate the end effector 102 to the left
relative to the shaft 104 by providing a lateral force to the left
side of the control 112. In response to force, the articulation
slide 208 may be pushed at least partially into the frame 212. As
the slide 208 is pushed into the frame 212, the slot 210 as well as
band portion 204 may be translated across the elongate shaft 104 in
a transverse direction, for example, a direction substantially
transverse, or perpendicular, to the longitudinal axis of the shaft
104. Accordingly, a force is applied to band portion 204, causing
it to resiliently bend and/or displace from its initial pre-bent
position toward the opposite side of the shaft 104. Concurrently,
band portion 202 is relaxed from its initial pre-bent position.
Such movement of the band portion 204, coupled with the
straightening of band portion 202, can apply a counter-clockwise
rotational force at boss 206 which in turn causes the boss 206 and
end effector 102 to pivot to the left about the articulation pivot
110 to a desired angle relative to the axis of the shaft 104 as
shown in FIG. 12. The relaxation of the band portion 202 decreases
the tension on that band portion, allowing the band portion 204 to
articulate the end effector 102 without substantial interference
from the band portion 202. It will be appreciated that the
clinician may also articulate the end effector 102 to the right
relative to the shaft 104 by providing a lateral force to the right
side of the control 112. This bends cable portion 202, causing a
clockwise rotational force at boss 206 which, in turn, causes the
boss 206 and end effector to pivot to the right about articulation
pivot 110. Similar to the above, band portion 204 can be
concurrently relaxed to permit such movement.
[0245] FIGS. 12 and 13 depict a motor-driven surgical cutting and
fastening instrument 310. This illustrated embodiment depicts an
endoscopic instrument and, in general, the instrument 310 is
described herein as an endoscopic surgical cutting and fastening
instrument; however, it should be noted that the invention is not
so limited and that, according to other embodiments, any instrument
disclosed herein may comprise a non-endoscopic surgical cutting and
fastening instrument. The surgical instrument 310 depicted in FIGS.
12 and 13 comprises a handle 306, a shaft 308, and an end effector
312 connected to the shaft 308. In various embodiments, the end
effector 312 can be articulated relative to the shaft 308 about an
articulation joint 314. Various means for articulating the end
effector 312 and/or means for permitting the end effector 312 to
articulate relative to the shaft 308 are disclosed in U.S. Pat. No.
7,753,245, entitled SURGICAL STAPLING INSTRUMENTS, which issued on
Jul. 13, 2010, and U.S. Pat. No. 7,670,334, entitled SURGICAL
INSTRUMENT HAVING AN ARTICULATING END EFFECTOR, which issued on
Mar. 2, 2010, the entire disclosures of which are incorporated by
reference herein. Various other means for articulating the end
effector 312 are discussed in greater detail below. Similar to the
above, the end effector 312 is configured to act as an endocutter
for clamping, severing, and/or stapling tissue, although, in other
embodiments, different types of end effectors may be used, such as
end effectors for other types of surgical devices, graspers,
cutters, staplers, clip appliers, access devices, drug/gene therapy
devices, ultrasound, RF and/or laser devices, etc. Several RF
devices may be found in U.S. Pat. No. 5,403,312, entitled
ELECTROSURGICAL HEMOSTATIC DEVICE, which issued on Apr. 4, 1995,
and U.S. patent application Ser. No. 12/031,573, entitled SURGICAL
CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES, filed Feb.
14, 2008, the entire disclosures of which are incorporated by
reference in their entirety.
[0246] It will be appreciated that the terms "proximal" and
"distal" are used herein with reference to a clinician gripping the
handle 306 of the instrument 310. Thus, the end effector 312 is
distal with respect to the more proximal handle 306. It will be
further appreciated that, for convenience and clarity, spatial
terms such as "vertical" and "horizontal" are used herein with
respect to the drawings. However, surgical instruments are used in
many orientations and positions, and these terms are not intended
to be limiting and absolute.
[0247] The end effector 312 can include, among other things, a
staple channel 322 and a pivotally translatable clamping member,
such as an anvil 324, for example. The handle 306 of the instrument
310 may include a closure trigger 318 and a firing trigger 320 for
actuating the end effector 312. It will be appreciated that
instruments having end effectors directed to different surgical
tasks may have different numbers or types of triggers or other
suitable controls for operating the end effector 312. The handle
306 can include a downwardly extending pistol grip 326 toward which
the closure trigger 318 is pivotally drawn by the clinician to
cause clamping or closing of the anvil 324 toward the staple
channel 322 of the end effector 312 to thereby clamp tissue
positioned between the anvil 324 and channel 322. In other
embodiments, different types of clamping members in addition to or
lieu of the anvil 324 could be used. The handle 306 can further
include a lock which can be configured to releasably hold the
closure trigger 318 in its closed position. More details regarding
embodiments of an exemplary closure system for closing (or
clamping) the anvil 324 of the end effector 312 by retracting the
closure trigger 318 are provided in U.S. Pat. No. 7,000,818,
entitled SURGICAL STAPLING INSTRUMENT HAVING SEPARATE DISTINCT
CLOSING AND FIRING SYSTEMS, which issued on Feb. 21, 2006, U.S.
Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL CUTTING AND
FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK, which issued
on Sep. 9, 2008, and U.S. Pat. No. 7,464,849, entitled
ELECTRO-MECHANICAL SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND
ANVIL ALIGNMENT COMPONENTS, which issued on Dec. 16, 2008, the
entire disclosures of which are incorporated by reference
herein.
[0248] Once the clinician is satisfied with the positioning of the
end effector 312, the clinician may draw back the closure trigger
318 to its fully closed, locked position proximate to the pistol
grip 326. The firing trigger 320 may then be actuated, or fired. In
at least one such embodiment, the firing trigger 320 can be farther
outboard of the closure trigger 318 wherein the closure of the
closure trigger 318 can move, or rotate, the firing trigger 320
toward the pistol grip 326 so that the firing trigger 320 can be
reached by the operator using one hand. in various circumstances.
Thereafter, the operator may pivotally draw the firing trigger 320
toward the pistol grip 312 to cause the stapling and severing of
clamped tissue in the end effector 312. Thereafter, the firing
trigger 320 can be returned to its unactuated, or unfired, position
(shown in FIGS. 1 and 2) after the clinician relaxes or releases
the force being applied to the firing trigger 320. A release button
on the handle 306, when depressed, may release the locked closure
trigger 318. The release button may be implemented in various forms
such as, for example, those disclosed in published U.S. Patent
Application Pub. No. 2007/0175955, entitled SURGICAL CUTTING AND
FASTENING INSTRUMENT WITH CLOSURE TRIGGER LOCKING MECHANISM, which
was filed on Jan. 31, 2006, the entire disclosure of which is
incorporated herein by reference in its entirety.
[0249] Further to the above, the end effector 312 may include a
cutting instrument, such as knife, for example, for cutting tissue
clamped in the end effector 312 when the firing trigger 320 is
retracted by a user. Also further to the above, the end effector
312 may also comprise means for fastening the tissue severed by the
cutting instrument, such as staples, RF electrodes, and/or
adhesives, for example. A longitudinally movable drive shaft
located within the shaft 308 of the instrument 310 may
drive/actuate the cutting instrument and the fastening means in the
end effector 312. An electric motor, located in the handle 306 of
the instrument 310 may be used to drive the drive shaft, as
described further herein. In various embodiments, the motor may be
a DC brushed driving motor having a maximum rotation of,
approximately, 25,000 RPM, for example. In other embodiments, the
motor may include a brushless motor, a cordless motor, a
synchronous motor, a stepper motor, or any other suitable electric
motor. A battery (or "power source" or "power pack"), such as a Li
ion battery, for example, may be provided in the pistol grip
portion 26 of the handle 6 adjacent to the motor wherein the
battery can supply electric power to the motor via a motor control
circuit. According to various embodiments, a number of battery
cells connected in series may be used as the power source to power
the motor. In addition, the power source may be replaceable and/or
rechargeable.
[0250] As outlined above, the electric motor in the handle 306 of
the instrument 310 can be operably engaged with the
longitudinally-movable drive member positioned within the shaft
308. Referring now to FIGS. 14-16, an electric motor 342 can be
mounted to and positioned within the pistol grip portion 326 of the
handle 306. The electric motor 342 can include a rotatable shaft
operably coupled with a gear reducer assembly 370 wherein the gear
reducer assembly 370 can include, among other things, a housing 374
and an output pinion gear 372. In certain embodiments, the output
pinion gear 372 can be directly operably engaged with a
longitudinally-movable drive member 382 or, alternatively, operably
engaged with the drive member 382 via one or more intermediate
gears 386. The intermediate gear 386, in at least one such
embodiment, can be meshingly engaged with a set, or rack, of drive
teeth 384 defined in the drive member 382. In use, the electric
motor 342 can be drive the drive member distally, indicated by an
arrow D (FIG. 15), and/or proximally, indicated by an arrow D (FIG.
16), depending on the direction in which the electric motor 342
rotates the intermediate gear 386. In use, a voltage polarity
provided by the battery can operate the electric motor 342 in a
clockwise direction wherein the voltage polarity applied to the
electric motor by the battery can be reversed in order to operate
the electric motor 342 in a counter-clockwise direction. The handle
306 can include a switch which can be configured to reverse the
polarity applied to the electric motor 342 by the battery. The
handle 306 can also include a sensor 330 configured to detect the
position of the drive member 382 and/or the direction in which the
drive member 382 is being moved.
[0251] As indicated above, the surgical instrument 310 can include
an articulation joint 314 about which the end effector 312 can be
articulated. The instrument 310 can further include an articulation
lock which can be configured and operated to selectively lock the
end effector 312 in position. In at least one such embodiment, the
articulation lock can extend from the proximal end of the shaft 308
to the distal end of the shaft 308 wherein a distal end of the
articulation lock can engage the end effector 312 to lock the end
effector 312 in position. Referring again to FIGS. 12 and 13, the
instrument 310 can further include an articulation control 316
which can be engaged with a proximal end of the articulation lock
and can be configured to operate the articulation lock between a
locked state and an unlocked state. In use, the articulation
control 316 can be pulled proximally to unlock the end effector 312
and permit the end effector 312 to rotate about the articulation
joint 314. After the end effector 312 has been suitably
articulated, the articulation control 316 can be moved distally to
re-lock the end effector 312 in position. In at least one such
embodiment, the handle 306 can further include a spring and/or
other suitable biasing elements configured to bias the articulation
control 316 distally and to bias the articulation lock into a
locked configuration with the end effector 312. If the clinician
desires, the clinician can once again pull the articulation control
316 back, or proximally, to unlock the end effector 312, articulate
the end effector 312, and then move the articulation control 316
back into its locked state. In such a locked state, the end
effector 312 may not articulate relative to the shaft 308.
[0252] As outlined above, the surgical instrument 310 can include
an articulation lock configured to hold the end effector 312 in
position relative to the shaft 308. As also outlined above, the end
effector 312 can be rotated, or articulated, relative to the shaft
308 when the articulation lock is in its unlocked state. In such an
unlocked state, the end effector 312 can be positioned and pushed
against soft tissue and/or bone, for example, surrounding the
surgical site within the patient in order to cause the end effector
312 to articulate relative to the shaft 308. In certain
embodiments, the articulation control 316 can comprise an
articulation switch or can be configured to operate an articulation
switch which can selectively permit and/or prevent the firing
trigger 320 from operating the electric motor 342. For instance,
such an articulation switch can be placed in series with the
electric motor 342 and a firing switch operably associated with the
firing trigger 320 wherein the articulation switch can be in a
closed state when the articulation control 316 is in a locked
state. When the articulation control 316 is moved into an unlocked
state, the articulation control 316 can open the articulation
switch thereby electrically decoupling the operation of the firing
trigger 320 and the operation of the electric motor 342. In such
circumstances, the firing drive of the instrument 310 cannot be
fired while the end effector 312 is in an unlocked state and is
articulatable relative to the shaft 308. When the articulation
control 316 is returned to its locked state, the articulation
control 316 can re-close the articulation switch which can then
electrically couple the operation of the firing trigger 320 with
the electric motor 342. Various details of one or more surgical
stapling instruments are disclosed in patent application Ser. No.
12/647,100, entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH
ELECTRIC ACTUATOR DIRECTIONAL CONTROL ASSEMBLY, which was filed on
Dec. 24, 2009, and which published on Jun. 30, 2011 as U.S. Patent
Application Publication No. 2011/0155785, the entire disclosure of
which are incorporated by reference herein.
[0253] Turning now to FIGS. 17-29, a surgical instrument 400 can
comprise a handle 403, a shaft 404 extending from the handle 403,
and an end effector 402 extending from the shaft 404. As the reader
will note, portions of the handle 403 have been removed for the
purposes of illustration; however, the handle 403 can include a
closure trigger and a firing trigger similar to the closure trigger
114 and the firing trigger 116 depicted in FIG. 1, for example. As
will be described in greater detail below, the firing trigger 116
can be operably coupled with a firing drive including a firing
member 470 extending through the shaft 404 wherein the operation of
the firing trigger 116 can advance the firing member 470 distally
toward the end effector 402. As will also be described in greater
detail below, the surgical instrument 400 can further include an
articulation drive which can be selectively coupled with the firing
member 470 such that, when the firing member 470 is motivated by
the firing trigger 116 and/or by a separate articulation trigger
and/or button, for example, the articulation drive can be driven by
the firing member 470 and the articulation drive can, in turn,
articulate the end effector 402 about an articulation joint
410.
[0254] Turning now to FIG. 17, the reader will note that the end
effector 402 of the surgical instrument 400 is illustrated in an
open configuration. More particularly, a first jaw of the end
effector 402 comprising an anvil 420 is illustrated in an open
position relative to a channel 498 of a second jaw of the end
effector 402. Similar to the above, the channel 498 can be
configured to receive and secure a staple cartridge therein.
Turning now to FIG. 20 which also illustrates the end effector 420
in an open configuration, the handle 403 of the surgical instrument
400 can include an articulation lock actuator 409 which can be
moved between a distal, or locked, position in which the end
effector 402 is locked in position relative to the shaft 404 and a
proximal, or unlocked, position in which the end effector 402 can
be articulated relative to the shaft 404 about the articulation
joint 410. Although the end effector 402 and the shaft 404 are
illustrated in FIG. 20 as being aligned in a straight
configuration, the articulation lock actuator 409 is illustrated in
its retracted, unlocked position and, as a result, the end effector
402 can be articulated relative to the shaft 404. Referring to
FIGS. 19, 24A and 24B, the articulation lock actuator 409 (FIG. 21)
can be operably coupled with an articulation lock 443 wherein the
articulation lock actuator 409 can move the articulation lock 443
between a distal position (FIG. 24A) in which the articulation lock
443 is engaged with a proximal lock member 407 of the end effector
402 and a proximal position (FIG. 24B) in which the articulation
lock 443 is disengaged from the end effector 402. As the reader
will appreciate, the distal, locked, position of the articulation
lock actuator 409 corresponds with the distal position of the
articulation lock 443 and the proximal, unlocked, position of the
articulation lock actuator 409 corresponds with the proximal
position of the articulation lock 443. Turning now to FIG. 19, the
articulation lock 443 is coupled to the articulation lock actuator
409 by an articulation lock bar 440 which comprises a distal end
442 engaged with the articulation lock 443, as better seen in FIG.
24A, and a proximal end 441 engaged with the articulation lock
actuator 409, as better seen in FIG. 22. As illustrated in FIGS.
24A and 24B, the articulation lock 443 can comprise one or more
teeth 445 which can be configured to meshingly engage one or more
teeth 446 defined around the perimeter of the proximal lock member
407, for example. Referring primarily to FIG. 19, the shaft 404 can
further comprise a biasing member, such as a spring 444, for
example, which can be configured to bias the teeth 445 of the
articulation lock 443 into engagement with the teeth 446 of the
proximal lock member 407 of the end effector 402. Similarly, the
handle 403 can further comprise a biasing member positioned within
the cavity 488 (FIG. 23) defined between the articulation lock
actuator 409 and the frame 480 such that the biasing member can
push the articulation lock actuator 409 towards its distal, locked,
position.
[0255] As illustrated in FIG. 17, the articulation lock actuator
409 can be comprised of two nozzle halves, or portions, 411a and
411b wherein, as the reader will note, the nozzle portion 411b has
been removed from FIGS. 18-27 for the purposes of illustration. As
also illustrated in FIG. 17, the articulation lock actuator 409 can
comprise a plurality of finger hooks 413 which can be grasped by
the surgeon, or other clinician, in order to retract the
articulation lock actuator 409 into its proximal, unlocked,
configuration. The articulation lock actuator 409, referring again
to FIG. 20, can further include a detent assembly 452 which can be
configured to bias a detent member 457 against the frame of the
shaft 404 or the frame of the handle 403. More particularly, the
shaft 404 can comprise a shaft frame 454 extending from a handle
frame 480 wherein the detent assembly 452 can be configured to bias
the detent member 457 against the shaft frame 454. Referring to
FIG. 19, the shaft frame 454 can include a detent channel 453
defined therein which can be aligned with the detent member 457
such that, as the articulation lock actuator 409 is slid between
its locked and unlocked positions described above, the detent
member 457 can slide within the detent channel 453. The detent
assembly 452, referring again to FIG. 20, can include a stationary
frame portion 458 which can define a threaded aperture configured
to receive an adjustable threaded member 459. The adjustable
threaded member 459 can include an internal aperture wherein at
least a portion of the detent member 457 can be positioned within
the internal aperture and wherein the detent member 457 can be
biased to the end of the internal aperture by a spring, for
example, positioned intermediate the detent member 457 and a closed
end of the internal aperture, for example. As illustrated in FIG.
19, the proximal end of the detent channel 453 can comprise a
detent seat 455 which can be configured to removably receive the
detent member 457 when the articulation lock actuator 409 has
reached its proximal, unlocked, position. In various circumstances,
the detent member 457, the detent seat 455, and the biasing spring
positioned in the adjustable threaded member 459 can be sized and
configured such that the detent assembly 452 can releasably hold
the articulation lock actuator 409 in its proximal, unlocked,
position. As described in greater detail below, the articulation
lock actuator 409 can be held in its proximal, unlocked, position
until the end effector 402 has been suitably articulated. At such
point, the articulation lock actuator 409 can be pushed forward to
disengage the detent member 457 from the detent seat 455. As the
reader will appreciate, referring primarily to FIG. 20, the
adjustable threaded member 459 can be rotated downwardly toward the
shaft frame 454 in order to increase the force needed to unseat the
detent member 457 from the detent seat 455 while the adjustable
threaded member 459 can be rotated upwardly away from the shaft
frame 454 in order to decrease the force needed to unseat the
detent member 457 from the detent seat 455. As also illustrated in
FIG. 20, the articulation lock actuator 409 can comprise an access
port 418 which can be utilized to access and rotate the threaded
member 459.
[0256] As discussed above, the articulation lock actuator 409 is in
a retracted, unlocked, position in FIG. 20 and the end effector 402
is in an unlocked configuration, as illustrated in FIG. 24B.
Referring now to FIGS. 19 and 20, the surgical instrument 400
further comprises an articulation driver 460 which can be pushed
distally to rotate the end effector 402 about the articulation
joint 410 in a first direction and pulled proximally to rotate the
end effector 402 about the articulation joint in a second, or
opposite, direction, as illustrated in FIG. 21. Upon comparing
FIGS. 20 and 21, the reader will note that the articulation driver
460 has been pulled proximally by the firing member 470. More
specifically, an intermediate portion 475 of the firing member 470
can comprise a notch, or slot, 476 defined therein which can be
configured to receive a proximal end 461 of the articulation driver
460 such that, when the firing member 470 is pulled proximally, the
firing member 470 can pull the articulation driver 460 proximally
as well. Similarly, when the firing member 470 is pushed distally,
the firing member 470 can push the articulation driver 460
distally. As also illustrated in FIGS. 20 and 21, the articulation
driver 460 can comprise a distal end 462 engaged with a projection
414 extending from the proximal lock member 407, for example, which
can be configured to transmit the proximal and distal articulation
motions of the articulation driver 460 to the end effector 102.
Referring primarily to FIGS. 18-20, the handle 404 can further
comprise a proximal firing member portion 482 of the firing member
470 including a distal end 481 engaged with a proximal end 477 of
the intermediate portion 475 of the firing member 470. Similar to
the above, the handle 403 can include an electric motor comprising
an output shaft and a gear operably engaged with the output shaft
wherein the gear can be operably engaged with a longitudinal set of
teeth 484 defined in a surface of the firing member portion 482. In
use, further to the above, the electric motor can be operated in a
first direction to advance the firing member 470 distally and a
second, or opposite, direction to retract the firing member 470
proximally. Although not illustrated, the handle 403 can further
comprise a switch which can be positioned in a first condition to
operate the electric motor in its first direction, a second
condition to operate the electric motor in its second direction,
and/or a neutral condition in which the electric motor is not
operated in either direction. In at least one such embodiment, the
switch can include at least one biasing member, such as a spring,
for example, which can be configured to bias the switch into its
neutral condition, for example. Also, in at least one such
embodiment, the first condition of the articulation switch can
comprise a first position of a switch toggle on a first side of a
neutral position and the second condition of the articulation
switch can comprise a second position of the switch toggle on a
second, or opposite, side of the neutral position, for example.
[0257] In various circumstances, further to the above, the
articulation switch can be used to make small adjustments in the
position of the end effector 402. For instance, the surgeon can
move the articulation switch in a first direction to rotate the end
effector 402 about the articulation joint in a first direction and
then reverse the movement of the end effector 402 by moving the
articulation switch in the second direction, and/or any other
suitable combinations of movements in the first and second
directions, until the end effector 402 is positioned in a desired
position. Referring primarily to FIGS. 19, 24A, and 24B, the
articulation joint 410 can include a pivot pin 405 extending from a
shaft frame member 451 and, in addition, an aperture 408 defined in
the proximal lock member 407 which is configured to closely receive
the pivot pin 405 therein such that the rotation of the end
effector 402 is constrained to rotation about an articulation axis
406, for example. Referring primarily to FIG. 19, the distal end of
the shaft frame 454 can include a recess 456 configured to receive
the shaft frame member 451 therein. As will be described in greater
detail below, the shaft 404 can include an outer sleeve which can
be slid relative to the shaft frame 454 in order to close the anvil
420. Referring primarily to FIGS. 19-21, the outer sleeve of the
shaft 410 can comprise a proximal portion 428 and a distal portion
426 which can be connected to one another by articulation links 430
and 432. When the outer sleeve is slid relative to the articulation
joint 410, the articulation links 430 can accommodate the angled
relative movement between the distal portion 426 and the proximal
portion 428 of the outer sleeve when the end effector 402 has been
articulated, as illustrated in FIG. 21. In various circumstances,
the articulation links 430 and 432 can provide two or more degrees
of freedom at the articulation joint 410 in order to accommodate
the articulation of the end effector 402. The reader will also note
that the articulation joint 410 can further include a guide 401
which can be configured to receive a distal cutting portion 472 of
the firing member 470 therein and guide the distal cutting portion
472 as it is advanced distally and/or retracted proximally within
and/or relative to the articulation joint 410.
[0258] As outlined above, the firing member 470 can be advanced
distally in order to advance the articulation driver 460 distally
and, as a result, rotate the end effector 402 in a first direction
and, similarly, the firing member 470 can be retracted proximally
in order to retract the articulation driver 460 proximally and, as
a result, rotate the end effector 402 in an opposite direction. In
some circumstances, however, it may be undesirable to move, or at
least substantially move, the distal cutting portion 472 of the
firing member 470 when the firing member 470 is being utilized to
articulate the end effector 402. Turning now to FIGS. 19-21, the
intermediate portion 475 of the firing member 470 can comprise a
longitudinal slot 474 defined in the distal end thereof which can
be configured to receive the proximal end 473 of the distal cutting
portion 472. The longitudinal slot 474 and the proximal end 473 can
be sized and configured to permit relative movement therebetween
and can comprise a slip joint 471. The slip joint 471 can permit
the intermediate portion 475 of the firing drive 470 to be moved to
articulate the end effector 402 without moving, or at least
substantially moving, the distal cutting portion 472. Once the end
effector 402 has been suitably oriented, the intermediate portion
475 can be advanced distally until a proximal sidewall of the
longitudinal slot 474 comes into contact with the proximal end 473
in order to advance the distal cutting portion 472 and fire the
staple cartridge positioned within the channel 498, as described in
greater detail further below. Referring primarily to FIG. 19, the
shaft frame 454 can comprise a longitudinal slot 469 defined
therein which can be configured to slidably receive the
articulation driver 460 and, similarly, the proximal portion 428 of
the outer shaft sleeve can comprise a longitudinal opening 425
configured to accommodate the relative movement between the
articulation driver 460 and the outer sleeve of the shaft 404
described above.
[0259] Further to the above, the articulation lock actuator 409 can
be configured to bias the proximal portion 461 of the articulation
driver 460 toward the drive member 470 when the articulation lock
actuator 409 is in its proximal, unlocked, position. More
particularly, in at least one such embodiment, the inner surface of
the articulation lock actuator 409 can comprise a cam which can
engage a lateral side 466 of the proximal portion 461 and bias the
proximal portion 461 into engagement with the slot 476 defined in
the intermediate portion 475 of the drive member 470. When the
articulation lock actuator 409 is moved back into its distal,
locked, position, the articulation lock actuator 409 may no longer
bias the proximal portion 461 inwardly toward the drive member 470.
In at least one such embodiment, the handle 403 and/or the shaft
404 can comprise a resilient member, such as a spring, for example,
which can be configured to bias the proximal portion 461 outwardly
away from the firing member 470 such that the proximal portion 461
is not operably engaged with the slot 476 unless the biasing force
of the resilient member is overcome by the articulation lock
actuator 409 when the articulation lock actuator 409 is moved
proximally into its unlocked position, as described above. In
various circumstances, the proximal portion 461 and the slot 476
can comprise a force-limiting clutch.
[0260] Once the end effector 402 has been articulated into the
desired orientation, further to the above, the closure trigger 114
can be actuated to move the anvil 420 toward its closed position,
as illustrated in FIG. 22. More particularly, the closure trigger
114 can advance the outer sleeve of the shaft 410 distally such
that the distal portion 426 of the outer sleeve can push the anvil
420 distally and downwardly, for example. The anvil 420 can
comprise projections 497 extending from opposite sides of the anvil
420 which can each be configured to slide and rotate within
elongate slots 499 defined in the cartridge channel 498. The anvil
420 can further comprise a projection 496 extending upwardly
therefrom which can be positioned within an aperture 495 defined in
the distal portion 426 of the outer sleeve wherein a sidewall of
the aperture 495 can contact the projection 496 as the distal
portion 426 is advanced distally to move the anvil 420 toward the
cartridge channel 498. The actuation of the closure drive, further
to the above, can also move the articulation lock actuator 409 from
its proximal, unlocked, position (FIGS. 20-22) into its distal,
locked, position (FIG. 23). More specifically, the closure drive
can be configured to advance a closure drive carriage 415 distally
which can contact a collar 450 mounted within the articulation
actuator 409, as illustrated in FIG. 22. As illustrated in FIGS. 19
and 22, the collar 450 can comprise opposing portions, or halves,
which can be assembled together such that the opposing portions of
the collar 450 can surround the shaft 404. The collar 450 can also
support the detent assembly 452, which is discussed above, and can
include a mounting portion engaged with the proximal end 441 of the
articulation lock bar 440, which is also discussed above. In any
event, the closure drive carriage 415 can contact the collar 450
and slide the articulation lock actuator 409 distally and, further
to the above, displace the detent member 457 from the detent seat
455, referring to FIG. 19, into the detent channel 453 such that
the articulation lock actuator 409 can be pushed into its locked
position and the articulation lock 443 can be moved into engagement
with the proximal lock portion 407 to lock the end effector 402 in
position, as illustrated in FIG. 23. At such point, the closure
drive carriage 415 can prevent the end effector 402 from being
unlocked and articulated until the closure drive and the anvil 420
is reopened and the closure drive carriage 415 is moved proximally,
as described in greater detail further below.
[0261] Referring now to FIG. 25, the actuation of the closure drive
by the closure drive actuator 114 and the distal advancement of the
outer sleeve 428 of the shaft 410 can also operably disengage the
articulation driver 460 from the firing drive 470. Upon reviewing
FIGS. 20 and 21 once again, the reader will note that the outer
sleeve 428 includes a window 424 defined therein within which a
rotatable cam member 465 can be positioned. The cam member 465 can
comprise a first end rotatably pinned or coupled to the shaft frame
454 and a second end configured to rotate relative to the pinned
end of the cam member 465 while, in other embodiments, the cam
member 465 can comprise any suitable shape. When the outer sleeve
428 is in its proximal position and the anvil 420 is in its open
configuration, the cam member 465 can be in a first position which
permits the proximal end 461 of the articulation driver 460 to be
engaged with the slot 476 defined in the firing member 470;
however, when the outer sleeve 428 is advanced distally, a sidewall
of the window 424 can engage the cam member 465 and lift the second
end of the cam member 465 away from the shaft frame 454 into a
second position. In this second position, the cam member 465 can
move the proximal end 461 of the articulation driver 460 away from
the firing drive 470 such that the proximal end 461 is no longer
positioned within the slot 476 defined in the firing drive 470.
Thus, when the closure drive has been actuated to close the anvil
420, the closure drive can push the articulation lock actuator 409
into its distal, locked, configuration, the articulation lock
actuator 409 can push the articulation lock 445 into a locked
configuration with the end effector 402, and, in addition, the
closure drive can operably disconnect the articulation driver 460
from the firing drive 470. At such point in the operation of the
surgical instrument 400, the actuation of the firing drive 470 will
not articulate the end effector 402 and the firing drive 470 can
move independently of the articulation driver 460.
[0262] Turning now to FIG. 26, as mentioned above, the firing drive
470 can be advanced distally to eject staples from a staple
cartridge positioned within the channel 498 of the end effector 402
and to deform the staples against the anvil 420. As outlined above,
the firing drive 470 can further comprise a cutting member which
can be configured to transect the tissue captured within the end
effector 402. As also mentioned above, the electric motor within
the handle 403 can be operated by the firing actuator 116 in order
to advance the firing member 470 distally wherein, in various
circumstances, the electric motor can be operated until the distal
cutting portion 472 of the firing member 470 reaches the distal end
of the staple cartridge and/or any other suitable position within
the staple cartridge. In any event, the rotation of the electric
motor can be reversed to retract the firing member 470 proximally,
as illustrated in FIG. 27. In various circumstances, the electric
motor can retract the proximal drive portion 482 and the
intermediate portion 475 until the distal sidewall of the
longitudinal slot 474 defined in the intermediate portion 475 comes
into contact with the proximal end 473 of the distal cutting member
472. At such point, the further retraction of the proximal drive
portion 482 and the intermediate portion 475 will retract the
distal cutting member 472 proximally. In various circumstances, the
electric motor can be operated until the slot 476 defined in the
intermediate portion 475 of the firing member 470 is realigned with
the proximal portion 461 of the articulation driver 460; however,
as the closure sleeve 428 is still in a distally advanced position,
the cam member 465 may still be biasing the articulation driver 460
out of engagement with the firing member 470. In order to permit
the articulation driver 460 to be re-engaged with the firing member
470, in such circumstances, the closure drive would have to be
re-opened to bring the window 424 defined in the outer sleeve
portion 428 into alignment with the cam member 465 such that the
cam member 465 can be pivoted inwardly toward the shaft frame 454
into its first position. In various circumstances, the articulation
driver 460 can be resiliently flexed out of engagement with the
firing member 470 such that, when the cam member 465 is permitted
to move back into its first position, the articulation driver 460
can resiliently flex inwardly toward the shaft frame 454 to
re-engage the proximal portion 461 of the articulation driver 460
with the slot 476 defined in the intermediate portion 475 of the
drive member 470. In various embodiments, the surgical instrument
400 can further comprise a biasing member which can be configured
to bias the proximal portion 461 back into engagement with the
intermediate portion 475.
[0263] The reader will note that the intermediate portion 475 of
the firing member 470 has been retracted proximally in FIG. 27 such
that the slot 476 defined in the intermediate portion 475 is
positioned proximally with respect to the proximal portion 461 of
the articulation driver 460. In such circumstances, as a result,
the proximal portion 461 may not be operably re-connected to the
firing member 470 until the intermediate portion 475 is advanced
distally to align the slot 476 with the proximal portion 461. Such
circumstances may arise as a result of the relative slip between
the intermediation portion 475 and the cutting member portion 472
of the firing member 470 created by the slip joint 471 which can be
addressed by momentarily re-actuating the electric motor in the
first direction, for example.
[0264] Referring again to FIG. 27, the firing member 470 may be in
a retracted or reset position, however, the closure drive is still
in an actuated, or closed, configuration which can prevent the
anvil 420 from being re-opened and the end effector 402 from being
re-articulated. When the closure drive is released, referring now
to FIG. 28, the closure drive carriage 415 can be retracted into a
proximal position in which the closure sleeve including portions
426 and 428 are pulled proximally as well. Referring again to FIG.
19, the proximal sleeve portion 428 can include a proximal end 417
which can be engaged with the closure drive carriage 415 such that
the proximal sleeve portion 428 and the closure drive carriage 415
move together in the distal direction and/or the proximal
direction. In any event, further to the above, the proximal
movement of the distal sleeve portion 426 can cause the distal
sidewall of the aperture 495 to engage the projection 496 extending
from the anvil 420 in order to pivot the anvil 420 into its open
position, as illustrated in FIG. 29. Furthermore, the proximal
movement of the closure drive carriage 415 can unlock the
articulation lock actuator 409 such that the articulation lock
actuator 409 can be moved into is proximal, unlocked, position
which can, as a result, pull the articulation lock 443 proximally
to compress the spring 444 and unlock the end effector 402. As
described above, the end effector 402 can be then articulated about
the articulation joint 410 and the operation of the surgical
instrument 400 described above can be repeated. Referring primarily
to FIGS. 18-20, the handle 404 can further comprise a switch 408
mounted to the handle frame 480 which can be configured to detect
whether the articulation lock actuator 409 is in its proximal,
unlocked, position. In some embodiments, the switch 408 can be
operably coupled with an indicator in the handle 404, such as
light, for example, which can indicate to the operator of the
surgical instrument 400 that the end effector 402 is in an unlocked
condition and that the operator may utilize the articulation switch
to articulate the end effector 402, for example.
[0265] As described above in connection with the embodiment of FIG.
17, the surgical instrument 400 can comprise an articulation lock
system configured to lock and unlock the end effector 402 and a
closure drive configured to open and close the anvil 420 of the end
effector 402. Although these two systems of the surgical instrument
400 interact in several respects, which are described above, the
systems can be actuated independently of one another in other
respects. For instance, the articulation lock actuator 409 and the
end effector lock 443 can be actuated without closing the anvil
420. In this embodiment of the surgical instrument 400, the closure
drive is operated independently to close the anvil 420. Turning now
to FIGS. 30-32, the surgical instrument 400 can include an
alternate arrangement in which the closure drive is actuated to,
one, close the anvil 420 and, two, lock the end effector 402 in
position. Referring primarily to FIGS. 31 and 32, the shaft 404 can
comprise an articulation lock bar 540 which can be moved between a
proximal, unlocked, position (FIG. 31) in which the end effector
402 can be articulated about the articulation joint 410 and a
distal, locked, position (FIG. 32) in which the end effector 402
can be locked in position. Similar to the articulation lock bar
440, the articulation lock bar 540 can include a distal end 542
which is operably engaged with the articulation lock 443 such that,
when the articulation lock bar 540 is pulled proximally, the
articulation lock 443 can be pulled proximally. Similarly, when the
articulation lock bar 540 is pushed distally, the articulation lock
443 can be pushed distally as well. In contrast to the articulation
lock bar 440 which is pushed distally and pulled proximally by the
articulation lock actuator 409, as described above, the
articulation lock bar 540 can be pushed distally and pulled
proximally by the closure sleeve 428. More particularly, the
proximal end 541 of the articulation lock bar 540 can comprise a
hook 547 which, when the closure sleeve 428 is pulled proximally,
can catch a portion of the closure sleeve 428 and be pulled
proximally with the closure sleeve 428. In such circumstances, the
sleeve 428 can pull the articulation lock bar 540 into an unlocked
condition. As the reader will note, the closure sleeve 428 can
include a window 549 within which the proximal end 541 of the
articulation lock bar 540 can be positioned. When the closure
sleeve 428 is pushed distally, further to the above, a proximal
sidewall 548 of the window 549 can contact the proximal end 541 and
push the articulation lock bar 540 and the articulation lock 443
distally in order to lock the end effector 402 in position.
[0266] As described herein, it may be desirable to employ surgical
systems and devices that may include reusable portions that are
configured to be used with interchangeable surgical components.
Referring to FIG. 33, for example, there is shown a surgical
system, generally designated as 1000, that, in at least one form,
comprises a surgical instrument 1010 that may or may not be reused.
The surgical instrument 1010 can be employed with a plurality of
interchangeable shaft assemblies 1200, 1200', 1200''. The
interchangeable shaft assemblies 1200, 1200', 1200'' may have a
surgical end effector 1300, 1300', 1300'' operably coupled thereto
that is configured to perform one or more surgical tasks or
procedures. For example, each of the surgical end effectors 1300,
1300', 1300'' may comprise a surgical cutting and fastening device
that is configured to operably support a surgical staple cartridge
therein. Each of the shaft assemblies may employ end effectors that
are adapted to support different sizes and types of staple
cartridges, have different shaft lengths, sizes, and types, etc.
While the present Figures illustrate end effectors that are
configured to cut and staple tissue, various aspects of the
surgical system 1000 may also be effectively employed with surgical
instruments that are configured to apply other motions and forms of
energy such as, for example, radio frequency (RF) energy,
ultrasonic energy and/or motion, to interchangeable shaft-mounted
end effector arrangements that are used in various surgical
applications and procedures. Furthermore, the end effectors, shaft
assemblies, handles, surgical instruments, and/or surgical
instrument systems can utilize any suitable fastener, or fasteners,
to fasten tissue. For instance, a fastener cartridge comprising a
plurality of fasteners removably stored therein can be removably
inserted into and/or attached to the end effector of a shaft
assembly. In various circumstances, a shaft assembly can be
selected to be attached to a handle of a surgical instrument and a
fastener cartridge can be selected to be attached to the shaft
assembly.
[0267] The surgical instrument 1010 depicted in the FIG. 33
comprises a housing 1040 that consists of a handle 1042 that is
configured to be grasped, manipulated and actuated by the
clinician. As the present Detailed Description proceeds, however,
it will be understood that the various unique and novel
arrangements of the various forms of interchangeable shaft
assemblies disclosed herein may also be effectively employed in
connection with robotically-controlled surgical systems. Thus, the
term "housing" may also encompass a housing or similar portion of a
robotic system that houses or otherwise operably supports at least
one drive system that is configured to generate and apply at least
one control motion which could be used to actuate the
interchangeable shaft assemblies disclosed herein and their
respective equivalents. The term "frame" may refer to a portion of
a handheld surgical instrument. The term "frame" may also represent
a portion of a robotically controlled surgical instrument and/or a
portion of the robotic system that may be used to operably control
a surgical instrument. For example, the interchangeable shaft
assemblies disclosed herein may be employed with various robotic
systems, instruments, components and methods disclosed in U.S.
Patent Application Publication No. US 2012/0298719. U.S. patent
application Ser. No. 13/118,241, entitled SURGICAL STAPLING
INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.
Patent Application Publication No. 2012/0298719, is incorporated by
reference herein in its entirety.
[0268] FIG. 34 illustrates the surgical instrument 1010 with an
interchangeable shaft assembly 1200 operably coupled thereto. In
the illustrated form, the surgical instrument includes a handle
1042. In at least one form, the handle 1042 may comprise a pair of
interconnectable housing segments 1044, 1046 that may be
interconnected by screws, snap features, adhesive, etc. See FIG.
35. In the illustrated arrangement, the handle housing segments
1044, 1046 cooperate to form a pistol grip portion 1048 that can be
gripped and manipulated by the clinician. As will be discussed in
further detail below, the handle 1042 operably supports a plurality
of drive systems therein that are configured to generate and apply
various control motions to corresponding portions of the
interchangeable shaft assembly that is operably attached
thereto.
[0269] The handle 1042 may further include a frame 1080 that
operably supports a plurality of drive systems. For example, the
frame 1080 can operably support a first or closure drive system,
generally designated as 1050, which may be employed to apply a
closing and opening motions to the interchangeable shaft assembly
1200 that is operably attached or coupled thereto. In at least one
form, the closure drive system 1050 may include an actuator in the
form of a closure trigger 1052 that is pivotally supported by the
frame 1080. More specifically, as illustrated in FIG. 35, the
closure trigger 1052 may be pivotally supported by frame 1080 such
that when the clinician grips the pistol grip portion 1048 of the
handle 1042, the closure trigger 1052 may be easily pivoted from a
starting or unactuated position to an actuated position and more
particularly to a fully compressed or fully actuated position. The
closure trigger 1052 may be biased into the unactuated position by
spring or other biasing arrangement (not shown). In various forms,
the closure drive system 1050 further includes a closure linkage
assembly 1060 that is pivotally coupled to the closure trigger
1052. As can be seen in FIG. 35, the closure linkage assembly 1060
may include a closure trigger 1052 that is pivotally coupled to a
closure link 1064 that has a pair of laterally extending attachment
lugs or portions 1066 protruding therefrom. The closure link 1064
may also be referred to herein as an "attachment member".
[0270] Still referring to FIG. 35, it can be observed that the
closure trigger 1052 may have a locking wall 1068 thereon that is
configured to cooperate with a closure release assembly 1070 that
is pivotally coupled to the frame 1080. In at least one form, the
closure release assembly 1070 may comprise a release button
assembly 1072 that has a distally protruding cam follower arm 1074
formed thereon. The release button assembly 1072 may be pivoted in
a counterclockwise direction by a release spring 1076. As the
clinician depresses the closure trigger 1052 from its unactuated
position towards the pistol grip portion 1048 of the handle 1042,
the closure link 1062 pivots upward to a point wherein the cam
follower arm 1072 drops into retaining engagement with the locking
wall 1068 on the closure link 1062 thereby preventing the closure
trigger 1052 from returning to the unactuated position. Thus, the
closure release assembly 1070 serves to lock the closure trigger
1052 in the fully actuated position. When the clinician desires to
unlock the closure trigger 1052 to permit it to be biased to the
unactuated position, the clinician simply pivots the closure
release button assembly 1072 such that the cam follower arm 1074 is
moved out of engagement with the locking wall 1068 on the closure
trigger 1052. When the cam follower arm 1074 has been moved out of
engagement with the closure trigger 1052, the closure trigger 1052
may pivot back to the unactuated position. Other closure trigger
locking and release arrangements may also be employed.
[0271] In at least one form, the handle 1042 and the frame 1080 may
operably support another drive system referred to herein as firing
drive system 1100 that is configured to apply firing motions to
corresponding portions of the interchangeable shaft assembly
attached thereto. The firing drive system may also be referred to
herein as a "second drive system". The firing drive system 1100 may
employ an electric motor 1102, located in the pistol grip portion
1048 of the handle 1042. In various forms, the motor 1102 may be a
DC brushed driving motor having a maximum rotation of,
approximately, 25,000 RPM, for example. In other arrangements, the
motor may include a brushless motor, a cordless motor, a
synchronous motor, a stepper motor, or any other suitable electric
motor. A battery 1104 (or "power source" or "power pack"), such as
a Li ion battery, for example, may be coupled to the handle 1042 to
supply power to a control circuit board assembly 1106 and
ultimately to the motor 1102. FIG. 34 illustrates a battery pack
housing 1104 that is configured to be releasably mounted to the
handle 1042 for supplying control power to the surgical instrument
1010. A number of battery cells connected in series may be used as
the power source to power the motor. In addition, the power source
may be replaceable and/or rechargeable.
[0272] As outlined above with respect to other various forms, the
electric motor 1102 can include a rotatable shaft (not shown) that
operably interfaces with a gear reducer assembly 1108 that is
mounted in meshing engagement with a with a set, or rack, of drive
teeth 1112 on a longitudinally-movable drive member 1110. In use, a
voltage polarity provided by the battery can operate the electric
motor 1102 in a clockwise direction wherein the voltage polarity
applied to the electric motor by the battery can be reversed in
order to operate the electric motor 1102 in a counter-clockwise
direction. When the electric motor 1102 is rotated in one
direction, the drive member 1110 will be axially driven in the
distal direction "D". When the motor 1102 is driven in the opposite
rotary direction, the drive member 1110 will be axially driven in a
proximal direction "P". See, for example, FIG. 35. The handle 1042
can include a switch which can be configured to reverse the
polarity applied to the electric motor 1102 by the battery. As with
the other forms described herein, the handle 1042 can also include
a sensor that is configured to detect the position of the drive
member 1110 and/or the direction in which the drive member 1110 is
being moved.
[0273] Actuation of the motor 1102 can be controlled by a firing
trigger 1120 that is pivotally supported on the handle 1042. The
firing trigger 1120 may be pivoted between an unactuated position
and an actuated position. The firing trigger 1120 may be biased
into the unactuated position by a spring (not shown) or other
biasing arrangement such that when the clinician releases the
firing trigger 1120, it may be pivoted or otherwise returned to the
unactuated position by the spring or biasing arrangement. In at
least one form, the firing trigger 1120 can be positioned
"outboard" of the closure trigger 1052 as was discussed above. In
at least one form, a firing trigger safety button 1122 may be
pivotally mounted to the closure trigger 1052. As can be seen in
FIGS. 35 and 36, for example, the safety button 1122 may be
positioned between the firing trigger 1120 and the closure trigger
1052 and have a pivot arm 1124 protruding therefrom. As shown in
FIG. 38, when the closure trigger 1052 is in the unactuated
position, the safety button 1122 is contained in the handle housing
where the clinician cannot readily access it and move it between a
safety position preventing actuation of the firing trigger 1120 and
a firing position wherein the firing trigger 1120 may be fired. As
the clinician depresses the closure trigger 1052, the safety button
1122 and the firing trigger 1120 pivot down wherein they can then
be manipulated by the clinician.
[0274] As indicated above, in at least one form, the longitudinally
movable drive member 1110 has a rack of teeth 1112 formed thereon
for meshing engagement with a corresponding drive gear 1114 of the
gear reducer assembly 1108. At least one form may also include a
manually-actuatable "bailout" assembly 1130 that is configured to
enable the clinician to manually retract the longitudinally movable
drive member 1110 should the motor become disabled. The bailout
assembly 1130 may include a lever or bailout handle assembly 1132
that is configured to be manually pivoted into ratcheting
engagement with the teeth 1112 in the drive member 1110. Thus, the
clinician can manually retract the drive member 1110 by using the
bailout handle assembly 1132 to ratchet the drive member in the
proximal direction "P". U.S. Patent Application Publication No. US
2010/0089970 discloses bailout arrangements and other components,
arrangements and systems that may also be employed with the various
instruments disclosed herein. U.S. patent application Ser. No.
12/249,117, entitled POWERED SURGICAL CUTTING AND STAPLING
APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM, now U.S. Patent
Application Publication No. 2010/0089970, is incorporated by
reference in its entirety.
[0275] FIGS. 34 and 37 illustrate one form of interchangeable shaft
assembly 1200 that has, for example, a surgical end effector 1300
operably attached thereto. The end effector 1300 as illustrated in
those Figures may be configured to cut and staple tissue in the
various manners disclosed herein. For example, the end effector
1300 may include a channel 1302 that is configured to support a
surgical staple cartridge 1304. The staple cartridge 1304 may
comprise a removable staple cartridge 1304 such that it may be
replaced when spent. However, the staple cartridge in other
arrangements may be configured such that once installed within the
channel 1302, it is not intended to be removed therefrom. The
channel 1032 and staple cartridge 1304 may be collectively referred
to as a "first jaw portion" of the end effector 1300. In various
forms, the end effector 1300 may have a "second jaw portion", in
the form of an anvil 1310, that is movably or pivotally supported
on the channel 1302 in the various manners discussed herein.
[0276] The interchangeable shaft assembly 1200 may further include
a shaft 1210 that includes a shaft frame 1212 that is coupled to a
shaft attachment module or shaft attachment portion 1220. In at
least one form, a proximal end 1214 of the shaft frame 1212 may
extend through a hollow collar portion 1222 formed on the shaft
attachment module 1220 and be rotatably attached thereto. For
example, an annular groove 1216 may be provided in the proximal end
1214 of the shaft frame 1212 for engagement with a U-shaped
retainer 1226 that extends through a slot 1224 in the shaft
attachment module 1220. Such arrangement enables the shaft frame
1212 to be rotated relative to the shaft attachment module
1220.
[0277] The shaft assembly 1200 may further comprise a hollow outer
sleeve or closure tube 1250 through which the shaft frame 1212
extends. The outer sleeve 1250 may also be referred to herein as a
"first shaft" and/or a "first shaft assembly". The outer sleeve
1250 has a proximal end 1252 that is adapted to be rotatably
coupled to a closure tube attachment yoke 1260. As can be seen in
FIG. 37, the proximal end 1252 of the outer sleeve 1250 is
configured to be received within a cradle 1262 in the closure tube
attachment yoke 1260. A U-shaped connector 1266 extends through a
slot 1264 in the closure tube attachment yoke 1260 to be received
in an annular groove 1254 in the proximal end 1252 of the outer
sleeve 1250. Such arrangement serves to rotatably couple the outer
sleeve 1250 to the closure tube attachment yoke 1260 such that the
outer sleeve 1250 may rotate relative thereto.
[0278] As can be seen in FIGS. 38 and 39, the proximal end 1214 of
the shaft frame 1214 protrudes proximally out of the proximal end
1252 of the outer sleeve 1250 and is rotatably coupled to the shaft
attachment module 1220 by the U-shaped retainer 1226 (shown in FIG.
38). The closure tube attachment yoke 1260 is configured to be
slidably received within a passage 1268 in the shaft attachment
module 1220. Such arrangement permits the outer sleeve 1250 to be
axially moved in the proximal direction "P" and the distal
direction "D" on the shaft frame 1212 relative to the shaft
attachment module 1220 as will be discussed in further detail
below.
[0279] In at least one form, the interchangeable shaft assembly
1200 may further include an articulation joint 1350. Other
interchangeable shaft assemblies, however, may not be capable of
articulation. As can be seen in FIG. 37, for example, the
articulation joint 1350 includes a double pivot closure sleeve
assembly 1352. According to various forms, the double pivot closure
sleeve assembly 1352 includes a shaft closure sleeve assembly 1354
having upper and lower distally projecting tangs 1356, 1358. An end
effector closure sleeve assembly 1354 includes a horseshoe aperture
1360 and a tab 1362 for engaging an opening tab on the anvil 1310
in the manner described above. As described above, the horseshoe
aperture 1360 and tab 1362 engage the anvil tab when the anvil 1310
is opened. An upper double pivot link 1364 includes upwardly
projecting distal and proximal pivot pins that engage respectively
an upper distal pin hole in the upper proximally projecting tang
1356 and an upper proximal pin hole in an upper distally projecting
tang 1256 on the outer sleeve 1250. A lower double pivot link 1366
includes downwardly projecting distal and proximal pivot pins that
engage respectively a lower distal pin hole in the lower proximally
projecting tang 1358 and a lower proximal pin hole in the lower
distally projecting tang 1258.
[0280] In use, the closure sleeve assembly 1354 is translated
distally (direction "D") to close the anvil 1310, for example, in
response to the actuation of the closure trigger 1052. The anvil
1310 is closed by distally translating the outer sleeve 1250, and
thus the shaft closure sleeve assembly 1354, causing it to strike a
proximal surface on the anvil 1310 in the manner described above.
As was also described above, the anvil 1310 is opened by proximally
translating the outer sleeve 1250 and the shaft closure sleeve
assembly 1354, causing tab 1362 and the horseshoe aperture 1360 to
contact and push against the anvil tab to lift the anvil 1310. In
the anvil-open position, the shaft closure sleeve assembly 1352 is
moved to its proximal position.
[0281] In at least one form, the interchangeable shaft assembly
1200 further includes a firing member 1270 that is supported for
axial travel within the shaft frame 1212. The firing member 1270
includes an intermediate firing shaft portion 1272 that is
configured for attachment to a distal cutting portion 1280. The
firing member 1270 may also be referred to herein as a "second
shaft" and/or a "second shaft assembly". As can be seen in FIG. 37,
the intermediate firing shaft portion 1272 may include a
longitudinal slot 1274 in the distal end thereof which can be
configured to receive the proximal end 1282 of the distal cutting
portion 1280. The longitudinal slot 1274 and the proximal end 1282
can be sized and configured to permit relative movement
therebetween and can comprise a slip joint 1276. The slip joint
1276 can permit the intermediate firing shaft portion 1272 of the
firing drive 1270 to be moved to articulate the end effector 1300
without moving, or at least substantially moving, the distal
cutting portion 1280. Once the end effector 1300 has been suitably
oriented, the intermediate firing shaft portion 1272 can be
advanced distally until a proximal sidewall of the longitudinal
slot 1272 comes into contact with the proximal end 1282 in order to
advance the distal cutting portion 1280 and fire the staple
cartridge positioned within the channel 1302, as described herein.
As can be further seen in FIG. 37, the shaft frame 1212 has an
elongate opening or window 1213 therein to facilitate assembly and
insertion of the intermediate firing shaft portion 1272 into the
shaft frame 1212. Once the intermediate firing shaft portion 1272
has been inserted therein, a top frame segment 1215 may be engaged
with the shaft frame 1212 to enclose the intermediate firing shaft
portion 1272 and distal cutting portion 1280 therein. The reader
will also note that the articulation joint 1350 can further include
a guide 1368 which can be configured to receive the distal cutting
portion 1280 of the firing member 1270 therein and guide the distal
cutting portion 1280 as it is advanced distally and/or retracted
proximally within and/or relative to the articulation joint
1350.
[0282] As can be seen in FIG. 37, the shaft attachment module 1220
may further include a latch actuator assembly 1230 that may be
removably attached to the shaft attachment module by cap screws
(not shown) or other suitable fasteners. The latch actuator
assembly 1230 is configured to cooperate with a lock yoke 1240 that
is pivotally coupled to the shaft attachment module 1220 for
selective pivotal travel relative thereto. See FIG. 41. Referring
to FIG. 39, the lock yoke 1240 may include two proximally
protruding lock lugs 1242 (FIG. 37) that are configured for
releasable engagement with corresponding lock detents or grooves
1086 formed in a frame attachment module portion 1084 of the frame
1080 as will be discussed in further detail below. The lock yoke
1240 is substantially U-shaped and is installed over the latch
actuator assembly 1230 after the latch actuator assembly 1230 has
been coupled to the shaft attachment module 1220. The latch
actuator assembly 1230 may have an arcuate body portion 1234 that
provides sufficient clearance for the lock yoke 1240 to pivot
relative thereto between latched and unlatched positions.
[0283] In various forms, the lock yoke 1240 is biased in the
proximal direction by spring or biasing member (not shown). Stated
another way, the lock yoke 1240 is biased into the latched position
(FIG. 40) and can be pivoted to an unlatched position (FIG. 41) by
a latch button 1236 that is movably supported on the latch actuator
assembly 1230. In at least one arrangement, for example, the latch
button 1236 is slidably retained within a latch housing portion
1235 and is biased in the proximal direction "P" by a latch spring
or biasing member (not shown). As will be discussed in further
detail below, the latch button 1236 has a distally protruding
release lug 1237 that is designed to engage the lock yoke 1240 and
pivot it from the latched position to the unlatched position shown
in FIG. 41 upon actuation of the latch button 1236.
[0284] The interchangeable shaft assembly 1200 may further include
a nozzle assembly 1290 that is rotatably supported on the shaft
attachment module 1220. In at least one form, for example, the
nozzle assembly 1290 can be comprised of two nozzle halves, or
portions, 1292, 1294 that may be interconnected by screws, snap
features, adhesive, etc. When mounted on the shaft attachment
module 1220, the nozzle assembly 1290 may interface with the outer
sleeve 1250 and shaft frame 1212 to enable the clinician to
selectively rotate the shaft 1210 relative to the shaft attachment
module 1220 about a shaft axis SA-SA which may be defined for
example, the axis of the firing member assembly 1270. In
particular, a portion of the nozzle assembly 1290 may extend
through a window 1253 in the outer sleeve to engage a notch 1218 in
the shaft frame 1212. See FIG. 37. Thus, rotation of the nozzle
assembly 1290 will result in rotation of the shaft frame 1212 and
outer sleeve 1250 about axis A-A relative to the shaft attachment
module 1220.
[0285] Referring now to FIGS. 42 and 43, the reader will observe
that the frame attachment module portion 1084 of the frame 1080 is
formed with two inwardly facing dovetail receiving slots 1088. Each
dovetail receiving slot 1088 may be tapered or, stated another way,
be somewhat V-shaped. See, for example, FIGS. 36 and 38 (only one
of the slots 1088 is shown). The dovetail receiving slots 1088 are
configured to releasably receive corresponding tapered attachment
or lug portions 1229 of a proximally-extending connector portion
1228 of the shaft attachment module 1220. As can be further seen in
FIGS. 37-39, a shaft attachment lug 1278 is formed on the proximal
end 1277 of the intermediate firing shaft 1272. As will be
discussed in further detail below, when the interchangeable shaft
assembly 1200 is coupled to the handle 1042, the shaft attachment
lug 1278 is received in a firing shaft attachment cradle 1113
formed in the distal end 1111 of the longitudinal drive member
1110. Also, the closure tube attachment yoke 1260 includes a
proximally-extending yoke portion 1265 that includes two capture
slots 1267 that open downwardly to capture the attachment lugs 1066
on the closure attachment bar 1064.
[0286] Attachment of the interchangeable shaft assembly 1220 to the
handle 1042 will now be described with reference to FIGS. 44-48. In
various forms, the frame 1080 or at least one of the drive systems
define an actuation axis AA-AA. For example, the actuation axis
AA-AA may be defined by the axis of the longitudinally-movable
drive member 1110. As such, when the intermediate firing shaft 1272
is operably coupled to the longitudinally movable drive member
1110, the actuation axis AA-AA is coaxial with the shaft axis SA-SA
as shown in FIG. 48.
[0287] To commence the coupling process, the clinician may position
the shaft attachment module 1220 of the interchangeable shaft
assembly 1200 above or adjacent to the frame attachment module
portion 1084 of the frame 1080 such that the attachment lugs 1229
formed on the connector portion 1228 of the shaft attachment module
1220 are aligned with the dovetail slots 1088 in the attachment
module portion 1084 as shown in FIG. 45. The clinician may then
move the shaft attachment module 1220 along an installation axis
IA-IA that is substantially transverse to the actuation axis AA-AA.
Stated another way, the shaft attachment module 1220 is moved in an
installation direction "ID" that is substantially transverse to the
actuation axis AA-AA until the attachment lugs 1229 of the
connector portion 1228 are seated in "operable engagement" with the
corresponding dovetail receiving slots 1088. See FIGS. 44 and 46.
FIG. 47 illustrates the position of the shaft attachment module
1220 prior to the shaft attachment lug 1278 on the intermediate
firing shaft 1272 entering the cradle 1113 in the longitudinally
movable drive member 1110 and the attachment lugs 1066 on the
closure attachment bar 1064 entering the corresponding slots 1267
in the yoke portion 1265 of the closure tube attachment yoke 1260.
FIG. 48 illustrates the position of the shaft attachment module
1220 after the attachment process has been completed. As can be
seen in that Figure, the lugs 1066 (only one is shown) are seated
in operable engagement in their respective slots 1267 in the yoke
portion 1265 of the closure tube attachment yoke 1260. As used
herein, the term "operable engagement" in the context of two
components means that the two components are sufficiently engaged
with each other so that upon application of an actuation motion
thereto, the components may carry out their intended action,
function and/or procedure.
[0288] As discussed above, referring again to FIGS. 44-49, at least
five systems of the interchangeable shaft assembly 1200 can be
operably coupled with at least five corresponding systems of the
handle 1042. A first system can comprise a frame system which
couples and/or aligns the frame of the shaft assembly 1200 with the
frame of the handle 1042. As outlined above, the connector portion
1228 of the shaft assembly 1200 can be engaged with the attachment
module portion 1084 of the handle frame 1080. A second system can
comprise a closure drive system which can operably connect the
closure trigger 1052 of the handle 1042 and the closure tube 1250
and the anvil 1310 of the shaft assembly 1200. As outlined above,
the closure tube attachment yoke 1260 of the shaft assembly 1200
can be engaged with the attachment lugs 1066 of the handle 1042. A
third system can comprise a firing drive system which can operably
connect the firing trigger 1120 of the handle 1042 with the
intermediate firing shaft 1272 of the shaft assembly 1200. As
outlined above, the shaft attachment lug 1278 can be operably
connected with the cradle 1113 of the longitudinal drive member
1110. A fourth system can comprise an electrical system which can,
one, signal to a controller in the handle 1042, such as
microcontroller 7004, for example, that a shaft assembly, such as
shaft assembly 1200, for example, has been operably engaged with
the handle 1042 and/or, two, conduct power and/or communication
signals between the shaft assembly 1200 and the handle 1042. For
instance, the shaft assembly 1200 can include six electrical
contacts and the electrical connector 4000 can also include six
electrical contacts wherein each electrical contact on the shaft
assembly 1200 can be paired and mated with an electrical contact on
the electrical connector 4000 when the shaft assembly 1200 is
assembled to the handle 1042. The shaft assembly 1200 can also
include a latch 1236 which can be part of a fifth system, such as a
lock system, which can releasably lock the shaft assembly 1200 to
the handle 1042. In various circumstances, the latch 1236 can close
a circuit in the handle 1042, for example, when the latch 1236 is
engaged with the handle 1042.
[0289] Further to the above, the frame system, the closure drive
system, the firing drive system, and the electrical system of the
shaft assembly 1200 can be assembled to the corresponding systems
of the handle 1042 in a transverse direction, i.e., along axis
IA-IA, for example. In various circumstances, the frame system, the
closure drive system, and the firing drive system of the shaft
assembly 1200 can be simultaneously coupled to the corresponding
systems of the handle 1042. In certain circumstances, two of the
frame system, the closure drive system, and the firing drive system
of the shaft assembly 1200 can be simultaneously coupled to the
corresponding systems of the handle 1042. In at least one
circumstance, the frame system can be at least initially coupled
before the closure drive system and the firing drive system are
coupled. In such circumstances, the frame system can be configured
to align the corresponding components of the closure drive system
and the firing drive system before they are coupled as outlined
above. In various circumstances, the electrical system portions of
the housing assembly 1200 and the handle 1042 can be configured to
be coupled at the same time that the frame system, the closure
drive system, and/or the firing drive system are finally, or fully,
seated. In certain circumstances, the electrical system portions of
the housing assembly 1200 and the handle 1042 can be configured to
be coupled before the frame system, the closure drive system,
and/or the firing drive system are finally, or fully, seated. In
some circumstances, the electrical system portions of the housing
assembly 1200 and the handle 1042 can be configured to be coupled
after the frame system has been at least partially coupled, but
before the closure drive system and/or the firing drive system are
have been coupled. In various circumstances, the locking system can
be configured such that it is the last system to be engaged, i.e.,
after the frame system, the closure drive system, the firing drive
system, and the electrical system have all been engaged.
[0290] As outlined above, referring again to FIGS. 44-49, the
electrical connector 4000 of the handle 1042 can comprise a
plurality of electrical contacts. Turning now to FIG. 197, the
electrical connector 4000 can comprise a first contact 4001a, a
second contact 4001b, a third contact 4001c, a fourth contact
4001d, a fifth contact 4001e, and a sixth contact 4001f, for
example. While the illustrated embodiment utilizes six contacts,
other embodiments are envisioned which may utilize more than six
contacts or less than six contacts. As illustrated in FIG. 197, the
first contact 4001a can be in electrical communication with a
transistor 4008, contacts 4001b-4001e can be in electrical
communication with a microcontroller 7004, and the sixth contact
4001f can be in electrical communication with a ground.
Microcontroller 7004 is discussed in greater detail further below.
In certain circumstances, one or more of the electrical contacts
4001b-4001e may be in electrical communication with one or more
output channels of the microcontroller 7004 and can be energized,
or have a voltage potential applied thereto, when the handle 1042
is in a powered state. In some circumstances, one or more of the
electrical contacts 4001b-4001e may be in electrical communication
with one or more input channels of the microcontroller 7004 and,
when the handle 1042 is in a powered state, the microcontroller
7004 can be configured to detect when a voltage potential is
applied to such electrical contacts. When a shaft assembly, such as
shaft assembly 1200, for example, is assembled to the handle 1042,
the electrical contacts 4001a-4001f may not communicate with each
other. When a shaft assembly is not assembled to the handle 1042,
however, the electrical contacts 4001a-4001f of the electrical
connector 4000 may be exposed and, in some circumstances, one or
more of the contacts 4001a-4001f may be accidentally placed in
electrical communication with each other. Such circumstances can
arise when one or more of the contacts 4001a-4001f come into
contact with an electrically conductive material, for example. When
this occurs, the microcontroller 7004 can receive an erroneous
input and/or the shaft assembly 1200 can receive an erroneous
output, for example. To address this issue, in various
circumstances, the handle 1042 may be unpowered when a shaft
assembly, such as shaft assembly 1200, for example, is not attached
to the handle 1042. In other circumstances, the handle 1042 can be
powered when a shaft assembly, such as shaft assembly 1200, for
example, is not attached thereto. In such circumstances, the
microcontroller 7004 can be configured to ignore inputs, or voltage
potentials, applied to the contacts in electrical communication
with the microcontroller 7004, i.e., contacts 4001b-4001e, for
example, until a shaft assembly is attached to the handle 1042.
Eventhough the microcontroller 7004 may be supplied with power to
operate other functionalities of the handle 1042 in such
circumstances, the handle 1042 may be in a powered-down state. In a
way, the electrical connector 4000 may be in a powered-down state
as voltage potentials applied to the electrical contacts
4001b-4001e may not affect the operation of the handle 1042. The
reader will appreciate that, eventhough contacts 4001b-4001e may be
in a powered-down state, the electrical contacts 4001a and 4001f,
which are not in electrical communication with the microcontroller
7004, may or may not be in a powered-down state. For instance,
sixth contact 4001f may remain in electrical communication with a
ground regardless of whether the handle 1042 is in a powered-up or
a powered-down state. Furthermore, the transistor 4008, and/or any
other suitable arrangement of transistors, such as transistor 4010,
for example, and/or switches may be configured to control the
supply of power from a power source 4004, such as a battery 1104
within the handle 1042, for example, to the first electrical
contact 4001a regardless of whether the handle 1042 is in a
powered-up or a powered-down state as outlined above. In various
circumstances, the latch 1236 of the shaft assembly 1200, for
example, can be configured to change the state of the transistor
4008 when the latch 1236 is engaged with the handle 1042. In
various circumstances, as described elsewhere herein, the latch
1236 can be configured to close a circuit when it engages the
handle 1042 and, as a result, affect the state of the transistor
4008. In certain circumstances, further to the below, a Hall effect
sensor 4002 can be configured to switch the state of transistor
4010 which, as a result, can switch the state of transistor 4008
and ultimately supply power from power source 4004 to first contact
4001a. In this way, further to the above, both the power circuits
and the signal circuits to the connector 4000 can be powered down
when a shaft assembly is not installed to the handle 1042 and
powered up when a shaft assembly is installed to the handle
1042.
[0291] In various circumstances, referring again to FIG. 197, the
handle 1042 can include the Hall effect sensor 4002, for example,
which can be configured to detect a detectable element, such as a
magnetic element, for example, on a shaft assembly, such as shaft
assembly 1200, for example, when the shaft assembly is coupled to
the handle 1042. The Hall effect sensor 4002 can be powered by a
power source 4006, such as a battery, for example, which can, in
effect, amplify the detection signal of the Hall effect sensor 4002
and communicate with an input channel of the microcontroller 7004
via the circuit illustrated in FIG. 197. Once the microcontroller
7004 has a received an input indicating that a shaft assembly has
been at least partially coupled to the handle 1042, and that, as a
result, the electrical contacts 4001a-4001f are no longer exposed,
the microcontroller 7004 can enter into its normal, or powered-up,
operating state. In such an operating state, the microcontroller
7004 will evaluate the signals transmitted to one or more of the
contacts 4001b-4001e from the shaft assembly and/or transmit
signals to the shaft assembly through one or more of the contacts
4001b-4001e in normal use thereof. In various circumstances, the
shaft assembly 1200 may have to be fully seated before the Hall
effect sensor 4002 can detect the magnetic element. While a Hall
effect sensor 4002 can be utilized to detect the presence of the
shaft assembly 1200, any suitable system of sensors and/or switches
can be utilized to detect whether a shaft assembly has been
assembled to the handle 1042, for example. In this way, further to
the above, both the power circuits and the signal circuits to the
connector 4000 can be powered down when a shaft assembly is not
installed to the handle 1042 and powered up when a shaft assembly
is installed to the handle 1042.
[0292] In various embodiments, any number of magnetic sensing
elements may be employed to detect whether a shaft assembly has
been assembled to the handle 1042, for example. For example, the
technologies used for magnetic field sensing include search coil,
fluxgate, optically pumped, nuclear precession, SQUID, Hall-effect,
anisotropic magnetoresistance, giant magnetoresistance, magnetic
tunnel junctions, giant magnetoimpedance,
magnetostrictive/piezoelectric composites, magnetodiode,
magnetotransistor, fiber optic, magnetooptic, and
microelectromechanical systems-based magnetic sensors, among
others.
[0293] After the interchangeable shaft assembly 1200 has been
operably coupled to the handle 1042, actuation of the closure
trigger 1052 will result in the distal axial advancement of the
outer sleeve 1250 and the shaft closure sleeve assembly 1354
coupled thereto to actuate the anvil 1310 in the various manners
disclosed herein. As can also be seen in FIG. 48, the firing member
1270 in the interchangeable shaft assembly 1200 is coupled to the
longitudinally movable drive member 1110 in the handle 1042. More
specifically, the shaft attachment lug 1278 formed on the proximal
end 1277 of the intermediate firing shaft 1272 is receive within
the firing shaft attachment cradle 1113 formed in the distal end
1111 of the longitudinally movable drive member 1110. Thus,
actuation of the firing trigger 1120 which results in powering of
the motor 1102 to axially advance the longitudinally movable drive
member 1110 will also cause the firing member 1270 to axially move
within the shaft frame 1212. Such action will cause the advancement
of the distal cutting portion 1280 through the tissue clamped in
the end effector 1300 in the various manners disclosed herein.
Although not observable in FIG. 48, those of ordinary skill in the
art will also understand that when in the coupled position depicted
in that Figure, the attachment lug portions 1229 of the shaft
attachment module 1220 are seated within their respective dovetail
receiving slots 1088 in the attachment module portion 1084 of the
frame 1080. Thus, the shaft attachment module 1220 is coupled to
the frame 1080. In addition, although not shown in FIG. 48 (but
which can be seen in FIG. 40), when the shaft attachment module
1220 has been coupled to the frame 1080, the lock lugs 1242 on the
lock yoke 1240 are seated within their respective lock grooves 1086
(only one is shown in FIG. 40) in the attachment module portion
1084 of the frame 1080 to releasably retain the shaft attachment
module 1220 in coupled operable engagement with the frame 1080.
[0294] To detach the interchangeable shaft assembly 1220 from the
frame 1080, the clinician pushes the latch button 1236 in the
distal direction "D" to cause the lock yoke 1240 to pivot as shown
in FIG. 41. Such pivotal movement of the lock yoke 1240 causes the
lock lugs 1242 thereon to move out of retaining engagement with the
lock grooves 1086. The clinician may then move the shaft attachment
module 1220 away from the handle in a disconnecting direction "DD"
as shown in FIG. 49.
[0295] Those of ordinary skill in the art will understand that the
shaft attachment module 1220 may also be held stationary and the
handle 1042 moved along the installation axis IA-IA that is
substantially transverse to the shaft axis SA-SA to bring the lugs
1229 on the connector portion 1228 into seating engagement with the
dovetail slots 1088. It will be further understood that the shaft
attachment module 1220 and the handle 1042 may be simultaneously
moved toward each other along the installation axis IA-IA that is
substantially transverse to the shaft axis SA-SA and the actuation
axis AA-AA.
[0296] As used herein, the phrase, "substantially transverse to the
actuation axis and/or to the shaft axis" refers to a direction that
is nearly perpendicular to the actuation axis and/or shaft axis. It
will be appreciated, however, that directions that deviate some
from perpendicular to the actuation axis and/or the shaft axis are
also substantially transverse to those axes.
[0297] FIGS. 50-57 illustrate another arrangement for coupling an
interchangeable shaft assembly 1600 to a frame 1480 of a handle
(not shown) that otherwise functions like the handle 1042 discussed
in detail herein. Thus, only those details necessary to understand
the unique and novel coupling features of the shaft assembly 1600
will be discussed in further detail. Those of ordinary skill in the
art will understand, however, that the frame may be supported
within a housing of a robotic system that otherwise operably
supports or houses a plurality of drive systems. In other
arrangements, the frame may comprise portion of a robotic system
for operably affixing interchangeable shaft assemblies thereto.
[0298] In at least one form, the shaft assembly 1600 includes a
shaft 1610 that may include all of the other components of shaft
1210 described above and may have an end effector (not shown) of
the type described above operably attached thereto. Turning to FIG.
57, in the illustrated arrangement, the shaft assembly 1600
includes a closure tube attachment yoke 1660 that may be rotatably
coupled to an outer sleeve 1650 in the manner in which the closure
tube yoke assembly 1260 was rotatably coupled to the outer sleeve
1250.
[0299] In various forms, the shaft assembly 1600 includes a shaft
attachment module or shaft attachment portion 1620 that has an open
bottom 1621. The shaft 1610 is coupled to the shaft attachment
module 1620 by inserting the proximal end of the shaft 1610 through
an opening 1622 in the shaft attachment module 1620. The closure
tube attachment yoke 1660 may be inserted into the shaft attachment
module 1620 through the open bottom portion 1621 such that the
proximal end 1652 of the outer sleeve 1650 is received within the
cradle 1662 in the closure tube attachment yoke 1660. In the manner
discussed above, a U-shaped connector 1666 is passed through a slot
1624 in the shaft attachment module 1620 to engage an annular
groove 1654 in the proximal end 1652 of the outer sleeve 1250 and
slots 1664 in the closure tube attachment yoke 1660 to affix the
outer sleeve 1650 to the closure tube attachment yoke 1660. As was
discussed above, such arrangement enables the outer sleeve 1650 to
rotate relative to the shaft attachment module 1620.
[0300] In at least one form, the closure tube attachment yoke 1660
is configured to be supported within the shaft attachment module
1620 such that the closure tube yoke attachment yoke 1660 may move
axially therein in the distal and proximal directions. In at least
one form, a closure spring 1625 is provided within the shaft
attachment module to bias the closure tube yoke assembly 1660 in
the proximal direction "P". See FIG. 57. As with the above
described shaft assembly 1210, the proximal end 1614 of the shaft
frame 1612 protrudes proximally out of the proximal end 1652 of the
outer sleeve 1650. As can be seen in FIG. 57 a retaining collar
1617 may be formed on the proximal end 1614 of the shaft frame
1612. A U-shaped retainer member 1627 is inserted through a lateral
slot 1633 in the shaft attachment module 1620 to retain the
proximal end 1652 of the outer sleeve in that axial position while
enabling the outer sleeve 1650 to rotate relative to the shaft
attachment module 1620. Such arrangement permits the clinician to
rotate the shaft 1610 about the shaft axis SA-SA relative to the
shaft attachment module 1620. Those of ordinary skill in the art
will appreciate that the shaft 1610 may be rotated by the same or
similar nozzle arrangement that was described above. For example,
the nozzle portions (not shown) may be assembled around the outer
sleeve 1650 and engage the notch 1618 in the shaft frame 1612
through the window 1653 in the outer sleeve 1650. See FIG. 53.
[0301] In at least one form, the frame 1480 has a frame attachment
module or frame attachment portion 1484 formed thereon or attached
thereto. The frame attachment module 1484 may be formed with
opposed dovetail receiving slots 1488. Each dovetail receiving slot
1488 may be tapered or, stated another way, be somewhat V-shaped.
The slots 1488 are configured to releasably receive corresponding
portion of a dovetail connector 1629 protruding from a proximal end
of the shaft attachment module 1620. As can be seen in FIG. 52, the
proximal end 1677 of the intermediate firing shaft 1672 protrudes
proximally out of the shaft attachment module 1620 and has a shaft
attachment lug 1678 formed thereon. The proximal end 1677 of the
intermediate firing shaft 1672 may extend through the space between
the end walls 1485 of the frame attachment module 1484 to enable
the shaft attachment lug 1678 formed thereon to be received in a
firing shaft attachment cradle 1513 formed in the distal end 1511
of the longitudinally moveable drive member 1510. See FIG. 57. When
the interchangeable shaft assembly 1600 is coupled to the handle or
housing or frame of the surgical instrument, device, robotic
system, etc., the shaft attachment lug 1678 is received in a firing
shaft attachment cradle 1513 formed in the distal end 1511 of the
longitudinally movable drive member 1510.
[0302] As can also be seen in FIGS. 52-55, the frame attachment
module 1484 may have a distally protruding bottom member 1490 that
is adapted to enclose at least a portion of the open bottom 1621 of
the shaft attachment module 1620 when the shaft attachment module
1620 is operably coupled to the frame attachment module 1484. In
one form, the closure tube attachment yoke 1660 has a pair of
proximally extending, spaced yoke arms 1661 protruding therefrom. A
transverse yoke attachment pin 1663 may extend therebetween. See
FIG. 57. When the shaft attachment module 1620 is brought into
operable engagement with the frame attachment module 1484, the yoke
attachment pin 1663 is configured to be hookingly engaged by a hook
1469 formed on a closure link 1467 of the closure drive system
1450. The closure drive system 1450 may be similar to the closure
drive system 1050 described above and include a closure trigger
1452 and a closure linkage assembly 1460. The closure linkage
assembly 1460 may include a closure link 1462 that is pivotally
coupled to the closure attachment bar 1464. The closure attachment
bar 1464 is pivotally coupled to the closure link 1467. See FIG.
54.
[0303] A method for coupling the shaft assembly 1600 to the frame
1480 may be understood from reference to FIGS. 53 and 54. As with
other arrangements disclosed herein, the shaft assembly 1600 may
define a shaft axis SA-SA and the frame 1480 may define an
actuation axis AA-AA. For example, the shaft axis SA-SA may be
defined by the firing member 1670 and the actuation axis AA-AA may
be defined by the longitudinally movable drive member 1510. To
commence the coupling process, the clinician may position the shaft
attachment module 1620 of the interchangeable shaft assembly 1600
above or adjacent to the frame attachment module 1484 of the frame
1480 such that the dovetail connector 1629 of the shaft attachment
module 1620 is aligned with the dovetail slots 1488 in the frame
attachment module 1484 as shown in FIG. 53. The clinician may then
move the shaft attachment module 1620 along an installation axis
IA-IA that is substantially transverse to the actuation axis AA-AA.
Stated another way, the shaft attachment module 1620 is moved in an
installation direction "ID" that is substantially transverse to the
actuation axis AA-AA until the dovetail connector 1629 is seated in
the dovetail slots 1488 in the frame module 1484. See FIGS. 55-57.
When the shaft attachment module 1620 has been operably engaged
with the frame attachment module 1484, the closure tube attachment
yoke 1665 will be operably engaged with the closure drive system
1450 and actuation of the closure trigger 1452 will result in the
distal axial advancement of the outer sleeve 1650 and the shaft
closure tube assembly coupled thereto to actuate the anvil in the
various manners disclosed herein. Likewise, the firing member 1270
will be operably engaged with the longitudinally movable drive
member 1510. See FIG. 57. Thus, actuation of the motor (not shown)
of the firing drive system 1500 will result in the axial
advancement of the longitudinally movable drive member 1510 as well
as the firing member 1670. Such action will cause the advancement
of the distal cutting portion of the firing member (not shown)
through the tissue clamped in the end effector in the various
manners disclosed herein.
[0304] FIGS. 58-62 illustrate another arrangement for coupling an
interchangeable shaft assembly 1900 to a frame 1780 of a handle
(not shown) that otherwise functions like the handle 1042 discussed
in detail herein. Thus, only those details necessary to understand
the unique and novel coupling features of the shaft assembly 1900
will be discussed in further detail. Those of ordinary skill in the
art will understand, however, that the frame may be supported
within a housing or other portion of a robotic system that
otherwise operably supports or houses a plurality of drive systems.
In other arrangements, the frame may comprise portion of a robotic
system for operably affixing interchangeable shaft assemblies
thereto.
[0305] In at least one form, the shaft assembly 1900 includes a
shaft 1910 that may include all of the other components of shaft
1210 described above and may have an end effector of the type
described above, for example, (not shown) operably attached
thereto. Turning to FIG. 62, in the illustrated arrangement, the
shaft assembly 1900 includes a closure tube attachment yoke 1960
that may be rotatably coupled to an outer sleeve 1950 in the manner
in which the closure tube yoke assembly 1260 was rotatably coupled
to the outer sleeve 1250.
[0306] In various forms, the shaft assembly 1900 may include a
shaft attachment module or shaft attachment portion 1920 that has
an open bottom 1921. The shaft 1910 is coupled to the shaft
attachment module 1920 by inserting the proximal end of the shaft
1910 through an opening 1922 in the shaft attachment module 1920.
The closure tube attachment yoke 1960 may be inserted into the
shaft attachment module 1920 through the open bottom portion 1921
such that the proximal end 1952 of the outer sleeve 1950 is
received within the cradle 1962 in the closure tube attachment yoke
1660. In the manner discussed above, a U-shaped connector 1966
engages an annular groove (not shown) in the proximal end 1952 of
the outer sleeve 1950 and slots 1964 in the closure tube attachment
yoke 1960 to affix the outer sleeve 1950 to the closure tube
attachment yoke 1960. As was discussed above, such arrangement
enables the outer sleeve 1950 to rotate relative to the shaft
attachment module 1920.
[0307] In at least one form, the closure tube attachment yoke 1960
is configured to be supported within the shaft attachment module
1920 such that the closure tube yoke assembly 1960 may move axially
therein in the distal ("D") and proximal ("P") directions. As with
the above described shaft assembly 1210, the proximal end of the
shaft frame protrudes proximally out of the proximal end 1952 of
the outer sleeve 1950. As can be seen in FIG. 62, a retaining
collar 1917 may be formed on the proximal end of the shaft frame. A
U-shaped retainer member 1927 may be employed to retain the
proximal end of the shaft frame in that axial position while
enabling the shaft frame to rotate relative to the shaft attachment
module 1920. Such arrangement permits the clinician to rotate the
shaft 1910 about the shaft axis SA-SA relative to the shaft
attachment module 1920. A nozzle assembly 1990 may be employed in
the various manners discussed herein to facilitate rotation of the
shaft 1910 relative to the shaft attachment module 1920.
[0308] The interchangeable shaft assembly 1900 may further include
a nozzle assembly 1990 that is rotatably supported on the shaft
attachment module 1920. In at least one form, for example, the
nozzle assembly 1990 can be comprised of two nozzle halves, or
portions that may be interconnected by screws, snap features,
adhesive, etc. When mounted on the shaft attachment module 1920,
the nozzle assembly 1990 may interface with a shaft rotation
adapter 1995 that is configured to engage the outer sleeve 1950 and
shaft frame 1912 to enable the clinician to selectively rotate the
shaft 1910 relative to the shaft attachment module 1920 about a
shaft axis SA-SA which may be defined for example, the axis of the
firing member assembly. Thus, rotation of the nozzle assembly 1990
will result in rotation of the shaft frame and outer sleeve 1950
about axis A-A relative to the shaft attachment module 1920.
[0309] In at least one form, the frame 1780 has a frame attachment
module or frame attachment portion 1784 formed thereon or attached
thereto. The frame attachment module 1784 may be formed with
outwardly facing dovetail receiving slots 1788. Each dovetail
receiving slot 1788 may be tapered or, stated another way, be
somewhat V-shaped. See FIG. 60. The slots 1788 are configured to
releasably operably engage corresponding inwardly-facing dovetail
connector portions 1929 formed on the shaft attachment module 1920.
As can be seen in FIG. 60, the proximal end 1977 of the
intermediate firing shaft 1972 protrudes proximally out of the
shaft attachment module 1920 and has a shaft attachment lug 1978
formed thereon. The shaft attachment lug 1978 is configured to be
received in a firing shaft attachment cradle 1813 formed in the
distal end 1811 of the longitudinally moveable drive member 1810.
See FIG. 62. When the interchangeable shaft assembly 1900 is in
operable engagement with the frame or housing of the surgical
instrument, device, robotic system, etc., the shaft attachment lug
1978 is received in operable engagement in a firing shaft
attachment cradle 1813 formed in the distal end 1811 of the
longitudinal drive member 1810.
[0310] In at least one form, the closure tube attachment yoke 1960
has a proximally extending yoke arm 1961 protruding therefrom that
has a downwardly open hook 1963 formed thereon to engage an
attachment lug 1766 formed on the closure attachment bar 1764 of
the closure drive system 1750. See FIG. 62. When the shaft
attachment module 1920 is brought into coupling engagement with the
frame attachment module 1784, the attachment lug 1766 is hookingly
engaged by a hook 1963 formed on the closure tube yoke arm 1961.
The closure drive system 1750 may be similar to the closure drive
system 1050 described above and include a closure trigger 1752 and
a closure linkage assembly 1760. The closure linkage assembly 1760
may include a closure link 1762 that is pivotally coupled to the
closure attachment bar 1764. See FIG. 62. Actuation of the closure
trigger 1752 will result in the axial movement of the closure
attachment bar 1764 in the distal direction "D".
[0311] As with other arrangements disclosed herein, the shaft
assembly 1900 may define a shaft axis SA-SA and the frame 1780 may
define an actuation axis AA-AA. For example, the shaft axis SA-SA
may be defined by the firing member 1970 and the actuation axis
AA-AA may be defined by the longitudinally movable drive member
1810 operably supported by the frame 1780. To commence the coupling
process, the clinician may position the shaft attachment module
1920 of the interchangeable shaft assembly 1900 above or adjacent
to the frame attachment module 1784 of the frame 1780 such that the
dovetail connector portions 1929 of the shaft attachment module
1920 are each aligned with their corresponding dovetail slot 1788
in the frame attachment module 1784. The clinician may then move
the shaft attachment module 1920 along an installation axis that is
substantially transverse to the actuation axis AA-AA. Stated
another way, the shaft attachment module 1920 is moved in an
installation direction that is substantially transverse to the
actuation axis AA-AA until the dovetail connectors 1929 are seated
in operable engagement in their corresponding dovetail slot 1788 in
the frame module 1784. When the shaft attachment module 1920 has
been attached to the frame attachment module 1784, the closure tube
attachment yoke 1960 will be operably coupled to the closure drive
system 1750 and actuation of the closure trigger 1752 will result
in the distal axial advancement of the outer sleeve 1950 and the
shaft closure tube assembly coupled thereto to actuate the anvil in
the various manners disclosed herein. Likewise, the firing member
will be coupled in operable engagement with the longitudinally
movable drive member 1810. See FIG. 62. Thus, actuation of the
motor (not shown) of the firing drive system 1800 will result in
the axial advancement of the longitudinally movable drive member
1810 as well as the firing member 1970. Such action will cause the
advancement of the distal cutting portion of the firing member (not
shown) through the tissue clamped in the end effector in the
various manners disclosed herein.
[0312] FIGS. 63-66 illustrate another arrangement for coupling an
interchangeable shaft assembly 2200 to a frame 2080 of a handle
(not shown) that may function like the handle 1042 discussed in
detail herein. Thus, only those details necessary to understand the
unique and novel coupling features of the shaft assembly 2200 will
be discussed in further detail. Those of ordinary skill in the art
will understand, however, that the frame may be supported within a
housing or other portion of a robotic system that otherwise
operably supports or houses a plurality of drive systems. In other
arrangements, the frame may comprise portion of a robotic system
for operably affixing interchangeable shaft assemblies thereto.
[0313] In at least one form, the shaft assembly 2200 includes a
shaft 2210 that may include all of the other components of shaft
1210 described above and may have an end effector (not shown) of
the type described above operably attached thereto. The various
constructions and operations of those features are described above.
In the illustrated arrangement, the shaft assembly 2200 includes a
closure tube attachment yoke 2260 that may be rotatably coupled to
an outer sleeve 2250 in the manner in which the closure tube yoke
attachment yoke 1260 was rotatably coupled to the outer sleeve
1250. The shaft assembly 2200, however, does not include a shaft
attachment module as was described above.
[0314] As can be seen in FIGS. 63-65, the frame 2080 may be formed
in first frame part 2080A and a second frame part 2080B. In those
applications wherein the frame 2080 is employed with a handle, the
first and second frame parts 2080A and 2080B may each be associated
with a handle housing portion. Thus, when the clinician desires to
attach a different shaft assembly 2200, the clinician may have to
detach the handle housing portions from each other. In such
arrangements for example, the housing portions may be connected
together by removable fasteners or other arrangements that
facilitate easy detachment of the housing portions. In other
embodiments, the shaft assembly 2200 may be configured for a single
use. In the illustrated arrangement, the first frame part 2080A may
operably support the various drive systems therein and the second
frame part 2080B may comprise a frame portion that retains the
various components of the shaft assembly 2200 in operable
engagement with their corresponding drive system components
supported by the first frame part 2080A.
[0315] In at least one form, the closure tube attachment yoke 2260
is configured to be supported within a passage 2081 in the frame
2080 such that the closure tube attachment yoke 2260 may move
axially therein in the distal and proximal directions. As with the
above described shaft assembly 1210, the proximal end 2214 of the
shaft frame 2212 protrudes proximally out of the proximal end of
the 2252 of the outer sleeve 2250. As can be seen in FIG. 63, a
retaining collar 2217 may be formed on the proximal end 2214 of the
shaft frame 2212. The retaining collar 2217 may be adapted to be
rotatably received within an annular groove 2083 formed in the
frame 2080. Such arrangement serves to operable couple the shaft
frame 2212 to the frame 2080 to prevent any relative axial movement
between those components while enabling the shaft frame 2212 to
rotate relative to the frame 2080. This arrangement further permits
the clinician to rotate the shaft 2210 about the shaft axis SA-SA
relative to the frame. Those of ordinary skill in the art will
appreciate that a nozzle arrangement that was described above may
be employed to rotate the shaft 2210 about the shaft axis SA-SA
relative to the frame 2080. For example, the nozzle portions (not
shown) may be assembled around the outer sleeve 2250 and engage the
notch 2218 in the shaft frame 2212 through the window 2253 in the
outer sleeve 2250. See FIG. 64.
[0316] As can be further seen in FIG. 64, the proximal end 2277 of
the intermediate firing shaft 2272 protrudes proximally out of the
proximal end 2214 of the shaft frame 2212 and has a shaft
attachment lug 2278 formed thereon. The firing shaft attachment
cradle 2113 formed in the distal end 2111 of the longitudinally
moveable drive member 2110 is formed to enable the firing shaft
attachment lug 2278 to be loaded from the side. In an effort to aid
the clinician in aligning the components of the shaft assembly 2220
and the first and second frame portions 2080A and 2080B during
assembly, the second frame portion 2080B may be provided with lugs
2090 that are configured to be received in corresponding holes or
pockets 2091 formed in the first frame portion 2080A and visa
versa. In those single use applications wherein it is not desirable
to be able to detach the shaft assembly 2200 from the frame 2080,
the pockets 2090 may be configured to permanently grip or engage
the lugs 2090 inserted therein.
[0317] The first frame portion 2080A and/or the longitudinally
movable drive member 2110 which is movably supported by the first
frame portion 2080A may define an actuation axis A-A and the shaft
assembly 2200 defines a shaft axis SA-SA. As can be seen in FIG.
64, to commence the coupling process, the shaft assembly 2200 and
the first frame portion 2080A may be oriented relative to each
other such that the shaft axis SA-SA is substantially parallel to
the actuation axis AA-AA and such that the collar 2217 is
laterally-aligned along an installation axis IA that is
substantially transverse to the actuation axis with the annular
groove 2083 and the shaft attachment lug 2278 is laterally aligned
along another installation axis IA-IA that is also substantially
transverse to the actuation axis AA-AA. The shaft assembly 2200 is
then moved in an installation direction "ID" that is substantially
transverse to the actuation axis AA-AA until the closure tube
attachment yoke 2260 is seated with the portion of the passage 2081
formed in the first frame portion 2080A, the collar 2217 is seated
within the portion of the annular groove 2083 formed in the first
frame portion 2080A and the shaft attachment lug 2278 is seated in
the shaft attachment cradle 2113 formed in the longitudinally
movable drive member 2110. In another arrangement, the shaft
assembly 2200 and the first frame portion 2080A may be brought
together in a similar manner by holding the shaft assembly 2200
stationary and moving the first frame portion 2080A toward the
handle assembly 2200 until the above-mentioned component portions
are operably seated together or the handle assembly 2200 and the
first frame portion 2080A may each be moved toward each other until
they are seated together. Once the handle assembly 2200 has been
operably seated within first frame portion 2080A as shown in FIG.
63, the second frame portion 2080B may be joined with the first
frame portion 2080A by aligning the posts 2090 with their
corresponding holes or pockets 2091 and joining the components
together. The first and second frame portions 2080A and 2080B may
be retained together by fasteners (e.g., screws, bolts, etc.),
adhesive and/or snap features. In still other arrangements, the
first frame portion 2080A and the second frame portion 2080B may be
retained together in coupled engagement when their respective
housing segments are joined together.
[0318] Once the first and second frame portions 2080A, 2080b have
been joined together as shown in FIGS. 65 and 66, the clinician may
then couple the closure drive system 2050 to the closure tube
attachment yoke 2260. The closure drive system 2050 may be similar
to the closure drive system 1050 described above and include a
closure trigger 2052 and a closure linkage assembly 2060. The
closure linkage assembly may include a closure link 2062 that is
pivotally coupled to the closure attachment bar 2064. In addition,
another closure link 2067 is pivotally coupled to the closure
attachment bar 2064. The closure link 2067 may be configured for
pivotal attachment to the arms 2261 of the closure tube attachment
yoke 2260 by a pin 2269. See FIG. 66.
[0319] FIGS. 68-74 illustrate another arrangement for coupling an
interchangeable shaft assembly 2500 to a frame 2380. The frame 2380
may be employed with handle as described herein or may be employed
in connection with a robotic system. In at least one form, the
shaft assembly 2500 includes a shaft 2510 that may include all of
the other components of shaft 1210 described above and may have an
end effector (not shown) of the type described above operably
attached thereto. The various constructions and operations of those
features are described above. As can be seen in FIGS. 68-74, the
shaft assembly 2500 includes a shaft attachment module or shaft
attachment portion 2520 that is configured to pivotally engage a
frame attachment module portion 2384 of the frame 2380 as will be
discussed in further detail below. The shaft attachment module
2520, for example, may have a collar portion 2522 through which the
proximal end of the shaft 2510 extends. The shaft attachment module
2520 cooperates with a frame attachment module portion 2384 of the
frame 2380 to form a passage 2581 therein for movably supporting a
closure tube attachment yoke 2560 therein. The closure tube yoke
assembly 2560 may be supported on a portion of the shaft attachment
module 2520 and is configured to be supported within the passage
2581 such that the closure tube yoke assembly 2560 may move axially
therein in the distal and proximal directions. As with the above
described shaft assemblies, the proximal end of the shaft frame
2512 is rotatably coupled to the shaft attachment module 2520 such
that it may rotate relative thereto. The proximal end of the outer
sleeve 2550 is rotatably coupled to the closure tube attachment
yoke 2560 in the above described manners such that it may rotate
relative thereto. In various forms, a nozzle 2590 may be employed
in the above-described manners to rotate the shaft 2510 about the
shaft axis SA-SA relative to the frame shaft attachment module
2520.
[0320] As can be further seen in FIG. 68-70, the proximal end 2577
of the intermediate firing shaft 2572 protrudes proximally out of
the closure tube attachment yoke 2560 and has a shaft attachment
lug 2578 formed thereon. The firing shaft attachment cradle 2413
formed in the distal end 2411 of the longitudinally moveable drive
member 2410 is formed to enable the firing shaft attachment lug
2578 to be pivotally be loaded from the side.
[0321] As can be seen in FIG. 69, the frame attachment module
portion 2384 has a pair of pivot cradles 2385 formed therein that
are adapted to receive corresponding pivot lugs 2529 formed on the
shaft attachment module 2520. When the lugs 2529 are supported
within the pivot cradles 2385, the shaft attachment module 2520 may
be pivoted into operable engagement with the frame attachment
module 2384 as illustrated in FIG. 70. In particular, the lugs 2529
may define a pivot axis PA-PA that may be substantially transverse
to the actuation axis AA-AA. See FIG. 73. The shaft attachment
module 2520 may have laterally protruding latch pins 2591 that are
configured to latchingly engage corresponding latch pockets 2387 in
the frame attachment module 2384. To initiate the coupling process,
the intermediate firing shaft 2572 is brought into operable
engagement with the longitudinally movable drive member in a
direction that is substantially transverse to the actuation axis
AA-AA.
[0322] Once the shaft attachment module 2520 has been latched to
the frame attachment module 2384 as shown in FIGS. 72 and 73, the
clinician may then couple the closure drive system (which may be
similar to the closure drive systems described herein) to the
closure tube attachment yoke 2560.
[0323] The various interchangeable shaft arrangements disclosed
herein represent vast improvements over prior surgical instrument
arrangements that employ dedicated shafts. For example, one shaft
arrangement may be used on multiple handle arrangements and/or with
robotically controlled surgical systems. The methods of coupling
the shaft arrangements also differ from prior shaft arrangements
that employ bayonet connections and other structures that require
the application of a rotary motion to the shaft and/or the handle
or housing during the coupling process. The various exemplary
descriptions of the coupling processes employed by the shaft
assemblies disclosed herein include bringing a portion of the
interchangeable shaft assembly into coupling engagement with a
corresponding portion of a housing, a handle, and/or a frame in a
direction or orientation that is substantially transverse to an
actuation axis. These coupling processes are intended to encompass
movement of either one or both of the shaft assembly and housing,
handle and/or frame during the coupling process. For example, one
method may encompass retaining the handle, housing and/or frame
stationary while moving the shaft assembly into coupling engagement
with it. Another method may encompass retaining the shaft assembly
stationary while moving the handle, housing and/or frame into
coupling engagement with it. Still another method may involve
simultaneously moving the shaft assembly and the handle, housing
and/or frame together into coupling engagement. It will be
understood that the coupling procedures employed for coupling the
various shaft assembly arrangements disclosed herein may encompass
one or more (including all) of such variations.
[0324] Referring to FIGS. 75-80, there is shown a handle 2642 that
may be substantially identical to the handle 1042 described above,
except that the frame attachment module or frame attachment portion
2684 of the frame 2680 includes a lockout assembly 2690 for
preventing the inadvertent actuation of the closure drive system
1750. As can be seen in FIGS. 75 and 76, for example, a proximal
lockout slot segment 2692 is formed in the frame attachment module
2684 such that, prior to attachment of the interchangeable shaft
assembly 1900' thereto, the corresponding attachment lug 1066 on
the closure attachment bar 1764 is slidably received therein. Thus,
when the closure attachment bar 1764 is in that position, the
clinician is unable to actuate the closure drive system. Stated
another way, when the actuation lug 1766 is received in the
proximal lockout slot segment 2692, the clinician is unable to
actuate the closure trigger 1752. In various forms, only one
proximal lockout slot segment 2692 may be employed. In other forms,
two proximal lockout slot segments 2692 are provided such that each
attachment lug 1766 may be received in a corresponding proximal
lockout slot segment 2692. In various forms, a lockout spring 2695
may be employed to bias the linkage assembly 1760, such that when
the closure trigger 1752 is in the unactuated position, the closure
attachment bar 1764 is biased to a position wherein at least one of
the attachment lugs 1766 is received in the proximal lockout slot
segment 2692.
[0325] As can be seen in FIGS. 77 and 78, the lockout assembly 2690
may further include a distal lug slot 2694 that is formed in the
shaft attachment module 1920' and located such that, when the shaft
attachment module 1920' has been completely attached to the frame
2680, the distal lug slot 2694 opens into the proximal lockout slot
segment 2692 as shown in FIGS. 77 and 78.
[0326] Operation of the closure lockout assembly 2690 may be
understood from reference to FIGS. 76-80. FIG. 76 illustrates the
position of the closure attachment bar 1764 when the closure
trigger 1752 is unactuated. As can be seen in that Figure, when in
that position, the attachment lug 1766 is received within the
proximal lockout slot segment 2692. Thus, if the clinician attempts
to actuate the closure trigger 1752 when in that position (i.e.,
prior to operably attaching the interchangeable shaft assembly
1900' to the frame 2680 in operable engagement), the clinician will
be unable to actuate the closure drive system 1750. After the
clinician has attached the interchangeable shaft assembly 1900' to
the frame 2684 such that it is fully seated and completely attached
in operable engagement, the distal lockout slot segment 2694 in the
shaft attachment module 1920'' will open into the proximal lockout
slot segment 2692 as shown in FIGS. 77 and 78. As the shaft
attachment module 1920' is inserted into operable engagement with
the frame attachment module 2684, the yoke arm 1961 protruding
proximally from the closure tube attachment yoke 1960 will capture
the attachment lug 1766 in the downwardly opening slot 1963 and
drive it to the bottom of the proximal lockout slot 2692 as shown
in FIG. 79. Thereafter, when the clinician desires to actuate the
closure drive system 1750 by actuating the closure trigger 1752,
the closure linkage assembly 1760 will be driven in the distal
direction "D". As the closure attachment bar 1764 is advanced
distally, the attachment lug 1766 is permitted to advance distally
into the distal lockout slot 2694 for the distance necessary, for
example, to result in the closure of the anvil or application of a
corresponding actuation motion to the end effector operably coupled
to the end effector shaft assembly 1900'. FIG. 80 illustrates the
position of the closure attachment bar 1764 when the closure drive
system 1750 has been fully actuated, for example, when the closure
trigger 1752 has been fully depressed.
[0327] FIGS. 81-85 illustrate another lockout assembly 2690' for
preventing the inadvertent actuation of the closure drive system
1750 until the interchangeable shaft assembly 1900' has been
coupled in operable engagement with the frame 2680. In at least one
form, a lockout shoulder 2696 is formed on the frame attachment
module or frame attachment portion 2684' such that when the
interchangeable shaft assembly 1900' has not been coupled in
operable engagement with the frame 2680, the closure attachment bar
1764 is prevented from moving in the distal direction "D" by the
shoulder 2696. See FIG. 81. As the shaft attachment module 1920' is
inserted into operable engagement with the frame attachment module
2684', the yoke arm 1961 protruding proximally from the closure
tube attachment yoke 1960 will capture the attachment lug 1766 on
the closure attachment bar 1764 a move the closure attachment bar
1764 to the "unlocked" position shown in FIGS. 82 and 83. As can be
particularly seen in FIG. 82, when in the unlocked position, the
closure attachment bar 1764 is located below the shoulder 2696 on
the frame attachment module 2684'. When the closure attachment bar
is in the unlocked position, it may be advanced distally when the
closure drive system 1750 is actuated by depressing the actuation
trigger 1752.
[0328] FIGS. 86-91 illustrate another interchangeable shaft
assembly 1900'' and handle 2642 that employs a lockout assembly
2700 for preventing the inadvertent actuation of the closure drive
system 1750''. As can be seen in FIGS. 88 and 89, one form of
lockout assembly 2700 includes an actuator slide member 2720 that
is slidably journaled in a distally extending lock foot 2710 formed
on the frame attachment module or frame attachment portion 2684''.
In particular, in at least one form, the actuator slide member 2720
has two laterally protruding slide tabs 2722 that are received in
corresponding slots 2712 formed in the lock foot 2710. See FIG. 86.
The actuator slide member 2720 is pivotally coupled to the closure
attachment bar 1764'' of the closure drive system 1750'' and has an
actuator pocket 2724 formed therein that is adapted to receive a
downwardly-protruding actuator tab 2702 on the closure tube
attachment yoke 1960'. As with the closure tube attachment yoke
1960 described above, the closure tube attachment closure yoke
1960' is rotatably affixed to the outer sleeve 1950 in the various
manners described herein and which is axially movable within the
shaft attachment module 1920'.
[0329] As can be seen in FIGS. 88-89, the lockout assembly 2700 may
further include a movable lock member 2730 that is received in a
cavity 2714 formed in the lock foot 2710. The lock member 2730 has
a lock portion 2732 that is sized to extend into the actuator
pocket 2724 such that when in that "locked" position, the lock
member 2730 prevents the distal movement of the actuator slide
member 2720 relative to the lock foot 2710. As can be most
particularly seen in FIG. 89, a lock spring 2734 is provided in the
cavity 2714 to bias the lock member 2730 into the locked
position.
[0330] FIG. 89 illustrates the lockout assembly 2700 in the locked
position. When in that position, the lock portion 2732 is located
in the actuator pocket 2724 and thereby prevents the distal
movement of the actuator slide member 2720. Thus, if the clinician
attempts to actuate the closure drive system 1750'' by depressing
the closure trigger 1752, the lock portion 2732 will prevent the
advancement of the slide member 2720. FIG. 90 illustrates the
position of the lock member 2730 after the actuator tab 2702 on the
closure tube yoke 1960' has been inserted into the actuator pocket
2724 and has biased the lock member 2370 into an "unlocked"
position in the bottom of the cavity 2714 wherein the actuator
slide member 2720 may be advanced distally. FIG. 91 illustrates the
position of the actuator slide 2720 after the closure trigger 1752
has been completely depressed to thereby axially advance the
closure tube attachment yoke 1960' and the outer sleeve 1950
attached thereto.
[0331] FIGS. 92-98 illustrate another interchangeable shaft
assembly 1900'' and handle 2642'' that employs a lockout assembly
2800 for preventing the inadvertent actuation of the closure drive
system 1750''. The closure drive system 1750'' may be similar to
the closure drive systems 1050 and 1750 described above and include
a closure trigger 1752 and a closure linkage assembly 1760'. The
closure linkage assembly 1760' may include a closure link 1762'
that is pivotally coupled to the closure attachment bar 1764. In
addition, an actuator slide member 2720 may be pivotally attached
to the closure attachment bar 1764 and also be slidably journaled
in a distally extending lock foot 2710' formed on the frame
attachment module 2684''. In particular, in at least one form, the
actuator slide member 2720 has two laterally protruding slide tabs
2722 that are received in corresponding slots 2712 formed in the
lock foot 2710. See FIG. 92. The actuator slide member 2720 is
pivotally coupled to the closure attachment bar 1764 of the closure
drive system 1750'' and has an actuator pocket 2724 formed therein
that is adapted to receive a downwardly-protruding actuator tab
2702 on the closure tube attachment yoke 1960'. As with the closure
tube attachment yoke 1960 described above, the closure tube
attachment closure yoke 1960' is rotatably affixed to the outer
sleeve 1950 in the various manners described herein and which is
axially movable within the shaft attachment module 1920''.
[0332] In various forms, the lockout assembly 2800 may further
include a movable lock bar or lock member 2802 that is pivotally
attached to the frame attachment module 2684''. For example, the
lock bar 2802 may be pivotally mounted to a laterally protruding
pin 2804 on the frame attachment module 2684''. The lock bar 2802
may further have a lock pin 2806 protruding from a proximal portion
thereof that is configured to extend into a lock slot 2808 provided
in the closure link 1762' when the closure drive system 1750'' in
unactuated. See FIG. 94. Lock pin 2806 may extend through a lock
slot 2812 that is provided in a side plate 2810 that is attached to
the frame 2680'. The lock slot 2812 may serve to guide the lock pin
2806 between locked (FIGS. 92-94) and unlocked positions (FIGS.
95-98).
[0333] When the lockout assembly is in the locked position, the
lock pin 2806 is received in the lock slot in 2808 in the closure
link 1762'. When in that position, the lock pin prevents movement
closure linkage assembly 1760'. Thus, if the clinician attempts to
actuate the closure drive system 1750'' by depressing the closure
trigger 1752, the lock pin 2806 will prevent movement of the
closure link 1762 and ultimately prevent the advancement of the
slide member 2720. FIGS. 95-98 illustrate the position of the lock
bar 2602 after the shaft attachment module 1920'' has been coupled
in operable engagement with the frame attachment module 2684''.
When in that position, a lock release portion 2820 on the frame
attachment module 2684'' contacts the lock bar 2802 and causes it
to pivot to thereby move the lock pin 2806 out of the lock slot
2808 in the closure link 1762'. As can also be seen in FIGS. 97 and
98, when the shaft attachment module 1920'' has been coupled in
operable engagement with the frame attachment module 2684'', the
actuator tab 2702 on the closure tube yoke 1960' is seated in the
actuator pocket 2724 in the actuator slide member 2720. FIG. 98
illustrates the position of the actuator slide member 2720 after
the closure trigger 1752 has been completely depressed to thereby
axially advance the closure tube attachment yoke 1960' and the
outer sleeve 1950 attached thereto in the distal direction "D".
[0334] Referring now to FIGS. 99-101, there is shown a shaft
locking assembly 2900 that is configured to prevent axial movement
of the firing member 1270 unless the interchangeable shaft assembly
has been coupled in operable engagement with the surgical
instrument. More particularly, the shaft locking assembly 2900 may
prevent axial movement of the firing member 1270 unless the firing
member has been coupled in operable engagement with the
longitudinally movable drive member 1110 (the longitudinally
movable drive member 1110 may be seen in FIG. 88). In at least one
form, the shaft locking assembly 2900 may comprise a shaft locking
member or locking plate 2902 that has a shaft clearance hole 2904
therethrough and is supported by a portion of the shaft attachment
frame or module 1920'' for slidable travel in directions "LD" that
are substantially transverse to the shaft axis SA-SA. See FIG. 99.
The shaft locking plate 2902 may, for example, move between a
locked position shown in FIG. 100 wherein the shaft locking plate
2902 extends into the recessed area 1279 between the attachment lug
1278 and the proximal end 1277 of the intermediate firing shaft
portion 1272. When in that locked position, the shaft locking plate
2902 prevents any axial movement of the intermediate firing shaft
portion 1272. The shaft locking plate 2902 may be biased into the
locked position by a lock spring 2906 or other biasing arrangement.
Note that FIG. 99 illustrates the locking plate 2902 in an unlocked
configuration for clarity purposes. When the interchangeable shaft
assembly is not attached to a surgical instrument, the locking
plate 2902 will be biased into the locked position as shown in FIG.
100. It will be appreciated that such arrangement prevents any
inadvertent axial movement of the firing member 1270 when the
interchangeable shaft assembly has not been attached in operable
engagement with a surgical instrument (e.g., hand-held instrument,
robotic system, etc.).
[0335] As was discussed in detail above, during the coupling of the
interchangeable shaft assembly to the surgical instrument, the
attachment lug 1278 on the end of the intermediate firing shaft
portion 1272 enters a cradle 1113 in the distal end of the
longitudinally movable drive member 1110. See FIG. 88. As the
attachment lug 1278 enters the cradle 1113, the distal end of the
longitudinally movable drive member 1110 contacts the shaft locking
plate 2902 and moves it to an unlocked position (FIG. 101) wherein
the distal end of the longitudinally movable drive member 1110 and
the proximal end 1277 of the intermediate firing shaft portion 1272
may axially move within the shaft clearance hole 2904 in response
to actuation motions applied to the longitudinally movable drive
member 1110.
[0336] Turning now to FIGS. 102-112, a surgical instrument, such as
surgical instrument 10000, and/or any other surgical instrument,
such as surgical instrument system 1000, for example, can comprise
a shaft 10010 and an end effector 10020, wherein the end effector
10020 can be articulated relative to the shaft 10010. Further to
the above, the surgical instrument 10000 can comprise a shaft
assembly comprising the shaft 10010 and the end effector 10020
wherein the shaft assembly can be removably attached to a handle of
the surgical instrument 10000. Referring primarily to FIGS.
102-104, the shaft 10010 can comprise a shaft frame 10012 and the
end effector 10020 can comprise an end effector frame 10022 wherein
the end effector frame 10022 can be rotatably coupled to the shaft
frame 10012 about an articulation joint 10090. With regard to the
articulation joint 10090, in at least one example, the shaft frame
10012 can comprise a pivot pin 10014 which can be received within a
pivot aperture 10024 defined in the end effector frame 10022. The
end effector frame 10022 can further comprise a drive pin 10021
extending therefrom which can be operably engaged with an
articulation driver. The drive pin 10021 can be configured to
receive a force applied thereto and, depending on the direction in
which the force is applied to the drive pin 10021, rotate the end
effector 10020 in a first direction or a second, opposite,
direction. More particularly, when a force is applied to the drive
pin 10021 in the distal direction by the articulation driver, the
articulation driver can push the drive pin 10021 around the pivot
pin 10014 and, similarly, when a force is applied to the drive pin
10021 in the proximal direction by the articulation driver, the
articulation driver can pull the drive pin 10021 around the pivot
pin 10014 in the opposite direction, for example. To the extent
that the drive pin 10021 were to be placed on the opposite side of
the articulation joint 10090, for example, the distal and proximal
movements of the articulation driver would produce an opposite
effect on the end effector 10020.
[0337] Further to the above, referring again to FIGS. 102-104, the
surgical instrument 10000 can comprise an articulation driver
system including a proximal articulation driver 10030 and a distal
articulation driver 10040. When a drive force is transmitted to the
proximal articulation driver 10030, whether it be in the proximal
direction or the distal direction, the drive force can be
transmitted to the distal articulation driver 10040 through an
articulation lock 10050, as described in greater detail further
below. In various circumstances, further to the above, a firing
member 10060 of the surgical instrument 10000 can be utilized to
impart such a drive force to the proximal articulation driver
10040. For instance, referring primarily to FIGS. 102-112, the
surgical instrument 10000 can comprise a clutch system 10070 which
can be configured to selectively connect the proximal articulation
driver 10030 to the firing member 10060 such that the movement of
the firing member 10060 can be imparted to the proximal
articulation driver 10030. In use, the clutch system 10070 can be
movable between an engaged state (FIGS. 102-108 and 111) in which
the proximal articulation driver 10030 is operably engaged with the
firing member 10060 and a disengaged state (FIGS. 109, 110, and
112) in which the proximal articulation driver 10030 is not
operably engaged with the firing member 10060. In various
circumstances, the clutch system 10070 can comprise an engagement
member 10072 which can be configured to directly connect the
proximal articulation driver 10030 to the firing member 10060. The
engagement member 10072 can comprise at least one drive tooth 10073
which can be received within a drive recess 10062 defined in the
firing member 10060 when the clutch system 10070 is in its engaged
state. In certain circumstances, referring primarily to FIGS. 28
and 31, the engagement member 10072 can comprise a first drive
tooth 10073 that extends to one side of the proximal articulation
driver 10030 and a second drive tooth 10073 that extends to the
other side of the proximal articulation driver 10030 in order to
engage the drive recess 10062 defined in the firing member
10060.
[0338] Further to the above, referring again to FIGS. 102-112, the
clutch system 10070 can further comprise an actuator member 10074
which can be configured to rotate or pivot the engagement member
10072 about a pivot pin 10071 mounted to a proximal end 10039 (FIG.
104A) of the proximal articulation driver 10030. The actuator
member 10074 can comprise a first, or outer, projection 10076 and a
second, or inner, projection 10077 between which can be defined a
recess 10078 configured to receive a control arm 10079 defined in
the engagement member 10072. When the actuator member 10074 is
rotated away from the firing member 10060, i.e., away from a
longitudinal axis of the shaft 10010, the inner projection 10077
can contact the control arm 10079 of the engagement member 10072
and rotate the engagement member 10072 away from the firing member
10060 to move the drive teeth 10073 out of the drive notch 10062
and, as a result, disengage the engagement member 10072 from firing
member 10060. Concurrently, the engagement member 10072 can also be
disengaged from the proximal articulation driver 10030. In at least
one circumstance, the proximal articulation driver 10030 can
comprise a drive notch 10035 defined therein which can also be
configured to receive a portion of the drive teeth 10073 when the
engagement member 10072 is in an engaged position wherein, similar
to the above, the drive teeth 10073 can be removed from the drive
notch 10035 when the engagement member 10072 is moved into its
disengaged position. In certain other circumstances, referring
primarily to FIG. 108, the drive teeth 10073 can define a recess
10083 therebetween which can be received in the drive notch 10035.
In either event, in a way, the engagement member 10072 can be
configured to, one, simultaneously engage the drive notch 10035 in
the proximal articulation driver 10030 and the drive notch 10062 in
the firing member 10060 when the engagement member 10072 is in its
engaged position and, two, be simultaneously disengaged from the
drive notch 10035 and the drive notch 10062 when the engagement
member 10072 is moved into its disengaged position. With continuing
reference to FIGS. 102-104, the actuator member 10074 can be
rotatably or pivotably mounted to a housing at least partially
surrounding the shaft 10010 via a pivot pin 10075. In some
circumstances, the pivot pin 10075 can be mounted to a handle frame
10001 and/or a handle housing surrounding the handle frame 10001,
such as a handle housing including portions 11002 and 11003 as
illustrated in FIG. 131, for example. The surgical instrument 10000
can further comprise a torsion spring 10080 at least partially
surrounding said pivot pin 10075 which can be configured to impart
a rotational bias to the actuator member 10074 in order to bias the
actuator 10074, and the engagement member 10072, toward the firing
member 10060 and to bias the engagement member 10072 into its
engaged position. To this end, the outer projection 10076 of the
actuator member 10074 can contact the control arm 10079 of the
engagement member 10072 and pivot the engagement member 10072
inwardly about the pivot pin 10071.
[0339] Upon comparing FIGS. 108 and 109, further to the above, the
reader will note that the clutch system 10070 has been moved
between its engaged state (FIG. 108) and its disengaged state (FIG.
109). A similar comparison can be drawn between FIGS. 111 and 112
wherein the reader will appreciate that a closure tube 10015 of the
shaft 10010 has been advanced from a proximal position (FIG. 111)
to a distal position (FIG. 112) to move clutch system 10070 between
its engaged state (FIG. 111) and its disengaged state (FIG. 112).
More particularly, the actuator member 10074 can include a cam
follower portion 10081 which can be contacted by the closure tube
10015 and displaced into its disengaged position when the closure
tube 10015 is advanced distally to close an anvil, for example, of
the end effector 10020. The interaction of a closure tube and an
anvil is discussed elsewhere in the present application and is not
repeated herein for the sake of brevity. In various circumstances,
referring primarily to FIG. 107, the cam follower portion 10081 of
the actuator member 10074 can be positioned within a window 10016
defined in the closure tube 10015. When the clutch system 10070 is
in its engaged state, the edge or sidewall 10017 of the window
10016 can contact the cam follower portion 10081 and pivot the
actuator member 10074 about the pivot pin 10075. In effect, the
sidewall 10017 of the window 10016 can act as a cam as the closure
tube 10015 is moved into its distal, or closed, position. In at
least one circumstance, the actuator member 10074 can comprise a
stop extending therefrom which can be configured to engage a
housing of the handle, for example, and limit the travel of the
actuator member 10074. In certain circumstances, the shaft assembly
can include a spring positioned intermediate the housing of the
shaft assembly and a ledge 10082 extending from the actuator member
10074 which can be configured to bias the actuator member 10074
into its engaged position. In the distal, closed, position of the
closure tube 10015, discussed above, the closure tube 10015 can
remain positioned underneath the cam follower portion 10081 to hold
the clutch system 10070 in its disengaged state. In such a
disengaged state, the movement of the firing member 10060 is not
transferred to the proximal articulation driver 10030, and/or any
other portion of the articulation driver system. When the closure
tube 10015 is retracted back into its proximal, or open, position,
the closure tube 10015 can be removed from underneath the cam
follower portion 10081 of the actuator member 10074 such that the
spring 10080 can bias the actuator member 10074 back into the
window 10016 and allow the clutch system 10070 to re-enter into its
engaged state.
[0340] When the proximal articulation driver 10030 is operatively
engaged with the firing member 10060 via the clutch system 10070,
further to the above, the firing member 10060 can move the proximal
articulation driver 10030 proximally and/or distally. For instance,
proximal movement of the firing member 10060 can move the proximal
articulation driver 10030 proximally and, similarly, distal
movement of the firing member 10060 can move the proximal
articulation driver 10030 distally. Referring primarily to FIGS.
102-104, movement of the proximal articulation driver 10030,
whether it be proximal or distal, can unlock the articulation lock
10050, as described in greater detail further below. With principal
reference to FIG. 102, the articulation lock 10050 can comprise a
frame which is co-extensive with a frame 10042 of the distal
articulation driver 10040. Collectively, the frame of the
articulation lock 10050 and the frame 10042 can be collectively
referred to hereinafter as frame 10042. The frame 10042 can
comprise a first, or distal, lock cavity 10044 and a second, or
proximal, lock cavity 10046 defined therein, wherein the first lock
cavity 10044 and the second lock cavity 10046 can be separated by
an intermediate frame member 10045. The articulation lock 10050 can
further include at least one first lock element 10054 at least
partially positioned within the first lock cavity 10044 which can
be configured to inhibit or prevent the proximal movement of the
distal articulation driver 10040. With regard to the particular
embodiment illustrated in FIGS. 102-104, there are three first lock
elements 10054 positioned within the first lock cavity 10044 which
can all act in a similar, parallel manner and can co-operatively
act as a single lock element. Other embodiments are envisioned
which can utilize more than three or less than three first lock
elements 10054. Similarly, the articulation lock 10050 can further
include at least one second lock element 10056 at least partially
positioned within the second lock cavity 10046 which can be
configured to inhibit or prevent the distal movement of the distal
articulation driver 10040. With regard to the particular embodiment
illustrated in FIGS. 102-104, there are three second lock elements
10056 positioned within the second lock cavity 10046 which can all
act in a similar, parallel manner and can co-operatively act as a
single lock element. Other embodiments are envisioned which can
utilize more than three or less than three second lock elements
10056.
[0341] Further to the above, referring primarily to FIG. 104A, each
first lock element 10054 can comprise a lock aperture 10052 and a
lock tang 10053. The lock tang 10053 can be disposed within the
first lock cavity 10044 and the lock aperture 10052 can be slidably
engaged with a frame rail 10011 mounted to the shaft frame 10012.
Referring again to FIG. 102, the frame rail 10011 extends through
the apertures 10052 in the first lock elements 10054. As the reader
will note, with further reference to FIG. 102, the first lock
elements 10054 are not oriented in a perpendicular arrangement with
the frame rail 10011; rather, the first lock elements 10054 are
arranged and aligned at a non-perpendicular angle with respect to
the frame rail 10011 such that the edges or sidewalls of the lock
apertures 10052 are engaged with the frame rail 10011. Moreover,
the interaction between the sidewalls of the lock apertures 10052
and the frame rail 10011 can create a resistive or friction force
therebetween which can inhibit relative movement between the first
lock elements 10054 and the frame rail 10011 and, as a result,
resist a proximal pushing force P applied to the distal
articulation driver 10040. Stated another way, the first lock
elements 10054 can prevent or at least inhibit the end effector
10020 from rotating in a direction indicated by arrow 10002. If a
torque is applied to the end effector 10020 in the direction of
arrow 10002, a proximal pushing force P will be transmitted from
the drive pin 10021 extending from the frame 10022 of the end
effector 10024 to the frame 10042 of the distal articulation driver
10040. In various circumstances, the drive pin 10021 can be closely
received within a pin slot 10043 defined in the distal end 10041 of
the distal articulation driver 10040 such that the drive pin 10021
can bear against a proximal sidewall of the pin slot 10043 and
transmit the proximal pushing force P to the distal articulation
driver 10040. Further to the above, however, the proximal pushing
force P will only serve to bolster the locking engagement between
the first lock elements 10054 and the frame rail 10011. More
particularly, the proximal pushing force P can be transmitted to
the tangs 10053 of the first lock elements 10054 which can cause
the first lock elements 10054 to rotate and decrease the angle
defined between first lock elements 10054 and the frame rail 10011
and, as a result, increase the bite between the sidewalls of the
lock apertures 10052 and the frame rail 10011. Ultimately, then,
the first lock elements 10054 can lock the movement of the distal
articulation driver 10040 in one direction.
[0342] In order to release the first lock elements 10054 and permit
the end effector 10020 to be rotated in the direction indicated by
arrow 10002, referring now to FIG. 103, the proximal articulation
driver 10030 can be pulled proximally to straighten, or at least
substantially straighten, the first lock elements 10054 into a
perpendicular, or at least substantially perpendicular, position.
In such a position, the bite, or resistive force, between the
sidewalls of the lock apertures 10052 and the frame rail 10011 can
be sufficiently reduced, or eliminated, such that the distal
articulation driver 10040 can be moved proximally. In order to
straighten the first lock elements 10054 into the position
illustrated in FIG. 103, the proximal articulation driver 10030 can
be pulled proximally such that a distal arm 10034 of the proximal
articulation driver 10030 contacts the first lock elements 10054 to
pull and rotate the first lock elements 10054 into their
straightened position. In various circumstances, the proximal
articulation driver 10030 can continue to be pulled proximally
until a proximal arm 10036 extending therefrom contacts, or abuts,
a proximal drive wall 10052 of the frame 10042 and pulls the frame
10042 proximally to articulate the end effector 10002. In essence,
a proximal pulling force can be applied from the proximal
articulation driver 10030 to the distal articulation driver 10040
through the interaction between the proximal arm 10036 and the
proximal drive wall 10052 wherein such a pulling force can be
transmitted through the frame 10042 to the drive pin 10021 to
articulate the end effector 10020 in the direction indicated by
arrow 10002. After the end effector 10020 has been suitably
articulated in the direction of arrow 10002, the proximal
articulation driver 10040 can be released, in various
circumstances, to permit the articulation lock 10050 to re-lock the
distal articulation member 10040, and the end effector 10020, in
position. In various circumstances, the articulation lock 10050 can
comprise a spring 10055 positioned intermediate the group of first
lock elements 10054 and the group of second lock elements 10056
which can be compressed when the first lock elements 10054 are
straightened to unlock the proximal movement of the distal
articulation driver 10040, as discussed above. When the proximal
articulation driver 10030 is released, the spring 10055 can
resiliently re-expand to push the first lock elements 10054 into
their angled positions illustrated in FIG. 102.
[0343] Concurrent to the above, referring again to FIGS. 102 and
103, the second lock elements 10056 can remain in an angled
position while the first lock elements 10054 are locked and
unlocked as described above. The reader will appreciate that,
although the second lock elements 10056 are arranged and aligned in
an angled position with respect to the shaft rail 10011, the second
lock elements 10056 are not configured to impede, or at least
substantially impede, the proximal motion of the distal
articulation driver 10040. When the distal articulation driver
10040 and articulation lock 10050 are slid proximally, as described
above, the second lock elements 10056 can slide distally along the
frame rail 10011 without, in various circumstances, changing, or at
least substantially changing, their angled alignment with respect
to the frame rail 10011. While the second lock elements 10056 are
permissive of the proximal movement of the distal articulation
driver 10040 and the articulation lock 10050, the second lock
elements 10056 can be configured to selectively prevent, or at
least inhibit, the distal movement of the distal articulation
driver 10040, as discussed in greater detail further below.
[0344] Similar to the above, referring primarily to FIG. 104A, each
second lock element 10056 can comprise a lock aperture 10057 and a
lock tang 10058. The lock tang 10058 can be disposed within the
second lock cavity 10046 and the lock aperture 10057 can be
slidably engaged with the frame rail 10011 mounted to the shaft
frame 10012. Referring again to FIG. 102, the frame rail 10011
extends through the apertures 10057 in the second lock elements
10056. As the reader will note, with further reference to FIG. 102,
the second lock elements 10056 are not oriented in a perpendicular
arrangement with the frame rail 10011; rather, the second lock
elements 10056 are arranged and aligned at a non-perpendicular
angle with respect to the frame rail 10011 such that the edges or
sidewalls of the lock apertures 10057 are engaged with the frame
rail 10011. Moreover, the interaction between the sidewalls of the
lock apertures 10057 and the frame rail 10011 can create a
resistive or friction force therebetween which can inhibit relative
movement between the second lock elements 10056 and the frame rail
10011 and, as a result, resist a distal force D applied to the
distal articulation driver 10040. Stated another way, the second
lock elements 10056 can prevent or at least inhibit the end
effector 10020 from rotating in a direction indicated by arrow
10003. If a torque is applied to the end effector 10020 in the
direction of arrow 10003, a distal pulling force D will be
transmitted from the drive pin 10021 extending from the frame 10022
of the end effector 10024 to the frame 10042 of the distal
articulation driver 10040. In various circumstances, the drive pin
10021 can be closely received within the pin slot 10043 defined in
the distal end 10041 of the distal articulation driver 10040 such
that the drive pin 10021 can bear against a distal sidewall of the
pin slot 10043 and transmit the distal pulling force D to the
distal articulation driver 10040. Further to the above, however,
the distal pulling force D will only serve to bolster the locking
engagement between the second lock elements 10056 and the frame
rail 10011. More particularly, the distal pulling force D can be
transmitted to the tangs 10058 of the second lock elements 10056
which can cause the second lock elements 10056 to rotate and
decrease the angle defined between second lock elements 10056 and
the frame rail 10011 and, as a result, increase the bite between
the sidewalls of the lock apertures 10057 and the frame rail 10011.
Ultimately, then, the second lock elements 10056 can lock the
movement of the distal articulation driver 10040 in one
direction.
[0345] In order to release the second lock elements 10056 and
permit the end effector 10020 to be rotated in the direction
indicated by arrow 10003, referring now to FIG. 104, the proximal
articulation driver 10030 can be pushed distally to straighten, or
at least substantially straighten, the second lock elements 10056
into a perpendicular, or at least substantially perpendicular,
position. In such a position, the bite, or resistive force, between
the sidewalls of the lock apertures 10057 and the frame rail 10011
can be sufficiently reduced, or eliminated, such that the distal
articulation driver 10040 can be moved distally. In order to
straighten the second lock elements 10056 into the position
illustrated in FIG. 104, the proximal articulation driver 10030 can
be pushed distally such that the proximal arm 10036 of the proximal
articulation driver 10030 contacts the second lock elements 10056
to push and rotate the second lock elements 10056 into their
straightened position. In various circumstances, the proximal
articulation driver 10030 can continue to be pushed distally until
the distal arm 10034 extending therefrom contacts, or abuts, a
distal drive wall 10051 of the frame 10042 and pushes the frame
10042 distally to articulate the end effector 10020. In essence, a
distal pushing force can be applied from the proximal articulation
driver 10030 to the distal articulation driver 10040 through the
interaction between the distal arm 10034 and the distal drive wall
10051 wherein such a pushing force can be transmitted through the
frame 10042 to the drive pin 10021 to articulate the end effector
10020 in the direction indicated by arrow 10003. After the end
effector 10020 has been suitably articulated in the direction of
arrow 10003, the proximal articulation driver 10040 can be
released, in various circumstances, to permit the articulation lock
10050 to re-lock the distal articulation member 10040, and the end
effector 10020, in position. In various circumstances, similar to
the above, the spring 10055 positioned intermediate the group of
first lock elements 10054 and the group of second lock elements
10056 can be compressed when the second lock elements 10056 are
straightened to unlock the distal movement of the distal
articulation driver 10040, as discussed above. When the proximal
articulation driver 10040 is released, the spring 10055 can
resiliently re-expand to push the second lock elements 10056 into
their angled positions illustrated in FIG. 102.
[0346] Concurrent to the above, referring again to FIGS. 102 and
104, the first lock elements 10054 can remain in an angled position
while the second lock elements 10056 are locked and unlocked as
described above. The reader will appreciate that, although the
first lock elements 10054 are arranged and aligned in an angled
position with respect to the shaft rail 10011, the first lock
elements 10054 are not configured to impede, or at least
substantially impede, the distal motion of the distal articulation
driver 10040. When the distal articulation driver 10040 and
articulation lock 10050 are slid distally, as described above, the
first lock elements 10054 can slide distally along the frame rail
10011 without, in various circumstances, changing, or at least
substantially changing, their angled alignment with respect to the
frame rail 10011. While the first lock elements 10054 are
permissive of the distal movement of the distal articulation driver
10040 and the articulation lock 10050, the first lock elements
10054 are configured to selectively prevent, or at least inhibit,
the proximal movement of the distal articulation driver 10040, as
discussed above.
[0347] In view of the above, the articulation lock 10050, in a
locked condition, can be configured to resist the proximal and
distal movements of the distal articulation driver 10040. In terms
of resistance, the articulation lock 10050 can be configured to
prevent, or at least substantially prevent, the proximal and distal
movements of the distal articulation driver 10040. Collectively,
the proximal motion of the distal articulation driver 10040 is
resisted by the first lock elements 10054 when the first lock
elements 10054 are in their locked orientation and the distal
motion of the distal articulation driver 10040 is resisted by the
second lock elements 10056 when the second lock elements 10056 are
in their locked orientation, as described above. Stated another
way, the first lock elements 10054 comprise a first one-way lock
and the second lock elements 10056 comprise a second one-way lock
which locks in an opposite direction.
[0348] When the first lock elements 10054 are in a locked
configuration, referring again to FIG. 102 and as discussed above,
an attempt to move the distal articulation driver 10040 proximally
may only serve to further decrease the angle between the first lock
elements 10054 and the frame rail 10011. In various circumstances,
the first lock elements 10054 may flex while, in at least some
circumstances, the first lock elements 10054 may abut a distal
shoulder 10047 defined in the first lock cavity 10044. More
precisely, the outer-most first lock element 10054 may abut the
distal shoulder 10047 while the other first lock elements 10054 may
abut an adjacent first lock element 10054. In some circumstances,
the distal shoulder 10047 can arrest the movement of the first lock
elements 10054. In certain circumstances, the distal shoulder 10047
can provide strain relief. For instance, once the distal shoulder
10047 is in contact with the first lock elements 10054, the distal
shoulder 10047 can support the first lock elements 10054 at a
location which is adjacent to, or at least substantially adjacent
to, the lock rail 10011 such that only a small lever arm, or torque
arm, separates opposing forces transmitted through the first lock
elements 10054 at different locations thereof. In such
circumstances, in effect, the force transmitted through the tangs
10053 of the first lock elements 10054 may be reduced or
eliminated.
[0349] Similar to the above, when the second lock elements 10056
are in a locked configuration, referring again to FIG. 102 and as
discussed above, an attempt to move the distal articulation driver
10040 distally may only serve to further decrease the angle between
the second lock elements 10056 and the frame rail 10011. In various
circumstances, the second lock elements 10056 may flex while, in at
least some circumstances, the second lock elements 10056 may abut a
proximal shoulder 10048 defined in the second lock cavity 10046.
More precisely, the outer-most second lock element 10056 may abut
the proximal shoulder 10048 while the other second lock elements
10056 may abut an adjacent second lock element 10056. In some
circumstances, the proximal shoulder 10048 can arrest the movement
of the second lock elements 10056. In certain circumstances, the
proximal shoulder 10048 can provide strain relief. For instance,
once the proximal shoulder 10048 is in contact with the second lock
elements 10056, the proximal shoulder 10048 can support the second
lock elements 10056 at a location which is adjacent to, or at least
substantially adjacent to, the lock rail 10011 such that only a
small lever arm, or torque arm, separates opposing forces
transmitted through the second lock elements 10056 at different
locations thereof. In such circumstances, in effect, the force
transmitted through the tangs 10058 of the second lock elements
10056 may be reduced or eliminated.
[0350] Discussed in connection with the exemplary embodiment
illustrated in FIGS. 102-112, an initial proximal movement of the
proximal articulation driver 10030 can unlock the proximal movement
of the distal articulation driver 10040 and the articulation lock
10050 while a further proximal movement of the proximal
articulation driver 10030 can drive the distal articulation driver
10040 and the articulation lock 10050 proximally. Similarly, an
initial distal movement of the proximal articulation driver 10030
can unlock the distal movement of the distal articulation driver
10040 and the articulation lock 10050 while a further distal
movement of the proximal articulation driver 10030 can drive the
distal articulation driver 10040 and the articulation lock 10050
distally. Such a general concept is discussed in connection with
several additional exemplary embodiments disclosed below. To the
extent that such discussion is duplicative, or generally
cumulative, with the discussion provided in connection with the
exemplary embodiment disclosed in FIGS. 102-112, such discussion is
not reproduced for the sake of brevity.
[0351] Turning now to FIGS. 113 and 114, a surgical instrument,
such as surgical instrument 10000, and/or any other surgical
instrument system, for example, can comprise a proximal
articulation driver 10130, a distal articulation driver 10140, and
an articulation lock 10150. The articulation lock 10150 can
comprise a frame 10152 which can include a slot, or lock channel,
10151 defined therein configured to receive at least a portion of
the proximal articulation driver 10130 and at least a portion of
the distal articulation driver 10140. The articulation lock 10150
can further comprise a first lock element 10154 positioned within a
first, or distal, lock cavity 10144 and a second lock element 10155
positioned within a second, or proximal, lock cavity 10146. Similar
to the above, the first lock element 10154 can be configured to
resist a proximal pushing force P transmitted through the distal
articulation driver 10140. To this end, the distal articulation
driver 10140 can include a lock recess 10145 defined therein which
can include one or more lock surfaces configured to engage the
first lock element 10154 and prevent the movement of the distal
articulation driver 10140 relative to the lock frame 10152. More
specifically, a sidewall of the lock recess 10145 can comprise a
first, or distal, lock surface 10141 which can be configured to
wedge the first lock element 10154 against a sidewall, or lock
wall, 10153 of the lock channel 10151 and, owing to this wedged
relationship, the distal articulation driver 10140 may not be able
to pass between the first lock element 10154 and the opposing
sidewall 10157 of the lock channel 10151. The reader will
appreciate that the lock recess 10145 is contoured such that it
gradually decreases in depth toward the distal end of the lock
recess 10145 wherein, correspondingly, the distal articulation
driver 10140 gradually increases in thickness toward the distal end
of the lock recess 10145. As a result, a proximal pushing force P
applied to the distal articulation driver 10140 may only serve to
further increase the resistance, or wedging force, holding the
distal articulation driver 10140 in position.
[0352] In order to pull the distal articulation driver 10140
proximally, the proximal articulation driver 10130 can be
configured to, one, displace the distal lock element 10154
proximally to unlock the articulation lock 10150 in the proximal
direction and, two, directly engage the distal articulation driver
10140 and apply a proximal pulling force thereto. More
specifically, further to the above, the proximal articulation
driver 10130 can comprise a distal arm 10134 configured to
initially engage the first lock element 10154 and a proximal arm
10136 which can be configured to then engage a proximal drive wall
10147 defined at the proximal end of the lock recess 10145 and pull
the distal articulation driver 10140 proximally. Similar to the
above, the proximal movement of the distal articulation driver
10140 can be configured to articulate the end effector of the
surgical instrument. Once the end effector has been suitably
articulated, the proximal articulation driver 10130 can be
released, in various circumstances, to permit a spring 10155
positioned intermediate the first lock element 10154 and the second
lock element 10156 to expand and sufficiently re-position the first
lock element 10154 relative to the first lock surface 10141 and
re-lock the distal articulation driver 10140 and the end effector
in position.
[0353] Concurrent to the above, the second lock element 10156 may
not resist, or at least substantially resist, the proximal movement
of the distal articulation driver 10140. When the articulation lock
10150 is in a locked condition, the second lock element 10156 may
be positioned between a second, or proximal, lock surface 10143 of
the lock recess 10145 and the lock wall 10153 of the lock channel
10151. As the distal articulation driver 10140 is pulled proximally
by the proximal articulation driver 10130, further to the above, a
dwell portion 10142 of the lock recess 10145 may move over the
second lock element 10156. In various circumstances, the dwell
portion 10142 of the lock recess 10145 may comprise the widest
portion of the recess 10145 which may, as a result, permit relative
sliding movement between the distal articulation driver 10140 and
the second lock element 10156 as the distal articulation driver
10140 is pulled proximally. In some circumstances, the second lock
element 10156 can be configured to roll within the dwell portion
10142 thereby reducing the resistance force between the distal
articulation driver 10140 and the second lock element 10156. As the
reader will appreciate, the second lock element 10156 may be
permissive to the proximal movement of the distal articulation
driver 10140 but can be configured to selectively resist the distal
movement of the distal articulation driver 10140 as discussed in
greater detail further below.
[0354] Similar to the above, the second lock element 10156 can be
configured to resist a distal pulling force D transmitted through
the distal articulation member 10140. To this end, the second lock
surface 10143 of the lock recess 10145 can be configured to wedge
the second lock element 10156 against the lock wall 10153 of the
lock channel 10151 and, owing to this wedged relationship, the
distal articulation driver 10140 may not be able to pass between
the second lock element 10156 and the opposing sidewall 10157 of
the lock channel 10151. The reader will appreciate that the lock
recess 10145 is contoured such that it gradually decreases in depth
toward the proximal end of the lock recess 10145 wherein,
correspondingly, the distal articulation driver 10140 gradually
increases in thickness toward the proximal end of the lock recess
10145. As a result, a distal pulling force D applied to the distal
articulation driver 10140 may only serve to further increase the
resistance, or wedging force, holding the distal articulation
driver 10140 in position.
[0355] In order to push the distal articulation driver 10140
distally, the proximal articulation driver 10130 can be configured
to, one, displace the second lock element 10156 distally to unlock
the articulation lock 10150 in the distal direction and, two,
directly engage the distal articulation driver 10140 and apply a
distal pushing force thereto. More specifically, further to the
above, the proximal arm 10136 of the proximal articulation driver
10130 can be configured to initially engage the second lock element
10156 wherein the distal arm 10134 can then engage a distal drive
wall 10148 defined at the distal end of the lock recess 10145 and
push the distal articulation driver 10140 distally. Similar to the
above, the distal movement of the distal articulation driver 10140
can be configured to articulate the end effector of the surgical
instrument. Once the end effector has been suitably articulated,
the proximal articulation driver 10130 can be released, in various
circumstances, to permit the spring 10155 to expand and
sufficiently re-position the second lock element 10156 relative to
the second lock surface 10143 in order to re-lock the distal
articulation driver 10140 and the end effector in position.
[0356] Concurrent to the above, the first lock element 10154 may
not resist, or at least substantially resist, the distal movement
of the distal articulation driver 10140. When the articulation lock
10150 is in a locked condition, the first lock element 10154 may be
positioned between the first lock surface 10141 of the lock recess
10145 and the lock wall 10153 of the lock channel 10151, as
discussed above. As the distal articulation driver 10140 is pushed
distally by the proximal articulation driver 10130, further to the
above, the dwell portion 10142 of the lock recess 10145 may move
over the first lock element 10154. In various circumstances, the
dwell portion 10142 may permit relative sliding movement between
the distal articulation driver 10140 and the first lock element
10154 as the distal articulation driver 10140 is pushed distally.
In some circumstances, the first lock element 10154 can be
configured to roll within the dwell portion 10142 thereby reducing
the resistance force between the distal articulation driver 10140
and the first lock element 10154. As the reader will appreciate,
the first lock element 10154 may be permissive to the distal
movement of the distal articulation driver 10140 but can
selectively resist the proximal movement of the distal articulation
driver 10140, as discussed above.
[0357] Further to the above, the first lock surface 10141, the
dwell 10142, and the second lock surface 10143 of the lock recess
10145 can define a suitable contour. Such a contour can be defined
by first, second, and third flat surfaces which comprise the first
lock surface 10141, the dwell 10142, and the second lock surface
10143, respectively. In such circumstances, definitive breaks
between the first lock surface 10141, the dwell 10142, and the
second lock surface 10143 can be identified. In various
circumstances, the first lock surface 10141, the dwell 10142, and
the second lock surface 10143 can comprise a continuous surface,
such as an arcuate surface, for example, wherein definitive breaks
between the first lock surface 10141, the dwell 10142, and the
second lock surface 10143 may not be present.
[0358] Turning now to FIGS. 115 and 116, a surgical instrument,
such as surgical instrument 10000, and/or any other surgical
instrument system, for example, can comprise a shaft 10210, an
articulation driver system comprising a proximal articulation
driver 10230 and a distal articulation driver 10240, and an
articulation lock 10250 configured to releasably hold the distal
articulation driver 10240 in position. The general operation of the
articulation driver system is the same as, or at least
substantially similar to, the articulation driver system discussed
in connection with the embodiment disclosed in FIGS. 113 and 114
and, as a result, such discussion is not repeated herein for the
sake of brevity. As the reader will appreciate, referring to FIGS.
115 and 116, the articulation lock 10250 can comprise a first lock
element 10254 which can provide a one-way lock configured to
releasably inhibit the proximal movement of the distal articulation
driver 10240 and a second lock element 10256 which can provide a
second one-way lock configured to releasably inhibit the distal
movement of the distal articulation driver 10240. Similar to the
above, the first lock element 10254 and the second lock element
10256 can be positioned within a lock recess 10245 defined in the
distal articulation driver 10240 and can be biased into a locked
condition by a biasing member, or spring, 10255, for example. In
order to unlock the first lock element 10254, similar to the above,
the proximal articulation driver 10230 can be pulled proximally
such that a distal hook 10234 contacts the first lock element 10254
and pulls the first lock element 10254 proximally. Thereafter, the
proximal articulation driver 10230 can be pulled further proximally
until the distal hook 10234 contacts the distal articulation driver
frame 10242 and pulls the distal articulation driver 10240
proximally and articulates the end effector 10020, similar to the
embodiments described above. In order to unlock the second lock
element 10256, similar to the above, the proximal articulation
driver 10230 can be pushed distally such that a proximal hook 10236
contacts the second lock element 10256 and pushes the second lock
element 10256 distally. Thereafter, the proximal articulation
driver 10230 can be pushed further distally until the proximal hook
10236 contacts the distal articulation driver frame 10242 and
pushes the distal articulation driver 10240 distally and articulate
the end effector 10020 in an opposite direction, similar to the
embodiments described above. In various circumstances, the first
lock element 10254 and the second lock element 10256 can each
comprise a rotatable spherical element, or bearing, for example,
which can be configured to reduce the sliding friction between the
lock elements 10254, 10256, the shaft frame 10212, the proximal
articulation driver 10230, and/or the distal articulation driver
10240.
[0359] Turning now to FIGS. 125-130, a surgical instrument, such as
surgical instrument 10000, and/or any other surgical instrument
system, for example, can comprise an articulation driver system
comprising a proximal articulation driver 10330 and a distal
articulation driver 10340, and an articulation lock 10350
configured to releasably hold the distal articulation driver 10340
in position. In many aspects, the general operation of the
articulation driver system is the same as, or at least
substantially similar to, the articulation driver system discussed
in connection with the embodiments disclosed above and, as a
result, such aspects are not repeated herein for the sake of
brevity. As the reader will appreciate, primarily referring to
FIGS. 125 and 126, the articulation lock 10350 can comprise a first
lock element 10354 which can provide a one-way lock configured to
releasably inhibit the proximal movement of the distal articulation
driver 10340 and a second lock element 10356 which can provide a
second one-way lock configured to releasably inhibit the distal
movement of the distal articulation driver 10340. Similar to the
above, the first lock element 10354 can be positioned within a
first, or distal, lock recess 10344 and the second lock element
10356 can be positioned within a second, or proximal, lock recess
10346 defined in the distal articulation driver 10340 and can be
biased into a locked condition by a biasing member, or spring,
10355, for example. In order to unlock the first lock element
10354, referring generally to FIG. 129, the proximal articulation
driver 10330 can be pulled proximally such that a distal hook 10334
contacts the first lock element 10354 and pulls the first lock
element 10354 proximally. Thereafter, as illustrated in FIG. 129,
the proximal articulation driver 10330 can be pulled further
proximally until the first lock element 10354 contacts an
intermediate shoulder 10345 extending from a frame 10342 of the
articulation driver frame 10340 and pulls the distal articulation
driver 10340 proximally to articulate the end effector, similar to
the embodiments described above. Once the end effector has been
sufficiently articulated, the proximal articulation driver 10330
can be released which can permit the biasing spring 10355 to
displace the lock elements 10354 and 10356 away from each other and
seat the lock elements 10354 and 10356 in a locked condition, as
illustrated in FIG. 130. In order to unlock the second lock element
10356, referring generally to FIG. 127, the proximal articulation
driver 10330 can be pushed distally such that a proximal hook 10336
contacts the second lock element 10356 and pushes the second lock
element 10356 distally. Thereafter, the proximal articulation
driver 10330 can be pushed further distally until the second lock
element 10356 contacts the intermediate shoulder 10345 of the
distal articulation driver frame 10342 and pushes the distal
articulation driver 10340 distally to articulate the end effector
in an opposite direction, similar to the embodiments described
above. Once the end effector has been sufficiently articulated,
similar to the above, the proximal articulation driver 10330 can be
released which can permit the biasing spring 10355 to displace the
lock elements 10354 and 10356 away from each other and seat the
lock elements 10354 and 10356 in a locked condition, as illustrated
in FIG. 128.
[0360] In various circumstances, further to the above, the first
lock element 10354 and the second lock element 10356 can each
comprise a wedge, for example, which can be configured to lock the
distal articulation driver 10340 in position. Referring primarily
again to FIGS. 125 and 126, the articulation lock 10350 can
comprise a frame 10352 including a lock channel 10351 defined
therein which can be configured to receive at least a portion of
the proximal articulation driver 10330 and at least a portion of
the distal articulation driver 10340. The first lock cavity 10344,
further to the above, can be defined between the distal
articulation driver 10340 and a lock wall 10353 of the lock channel
10351. When a proximal load P is transmitted to the distal
articulation driver 10340 from the end effector, the distal
articulation driver 10340 can engage a wedge portion 10358 of the
first lock element 10354 and bias the first lock element 10354
against the lock wall 10353. In such circumstances, the proximal
load P may only increase the wedging force holding the first lock
element 10354 in position. In effect, the first lock element 10354
can comprise a one-way lock which can inhibit the proximal movement
of the distal articulation driver 10340 until the first lock
element 10354 is unlocked, as described above. When the first lock
element 10354 is unlocked and the distal articulation driver 10340
is being moved proximally, the second lock element 10356 may not
resist, or at least substantially resist, the proximal movement of
the distal articulation driver 10340. Similar to the above, the
second lock cavity 10346, further to the above, can be defined
between the distal articulation driver 10340 and the lock wall
10353. When a distal load D is transmitted to the distal
articulation driver 10340 from the end effector, the distal
articulation driver 10340 can engage a wedge portion 10359 of the
second lock element 10356 and bias the second lock element 10356
against the lock wall 10353. In such circumstances, the distal load
D may only increase the wedging force holding the second lock
element 10356 in position. In effect, the second lock element 10356
can comprise a one-way lock which can inhibit the distal movement
of the distal articulation driver 10340 until the second lock
element 10356 is unlocked, as described above. When the second lock
element 10356 is unlocked and the distal articulation driver 10340
is being moved distally, the first lock element 10354 may not
resist, or at least substantially resist, the distal movement of
the distal articulation driver 10340.
[0361] Turning now to FIGS. 117-124, a surgical instrument, such as
surgical instrument 10000, and/or any other surgical instrument
system, for example, can comprise an articulation driver system
comprising a proximal articulation driver 10430 and a distal
articulation driver 10440, and an articulation lock 10450
configured to releasably hold the distal articulation driver 10440
in position. As the reader will appreciate, primarily referring to
FIGS. 117 and 118, the articulation lock 10450 can comprise a first
lock cam 10454 which can provide a one-way lock configured to
releasably inhibit the distal movement of the distal articulation
driver 10440 and a second lock cam 10456 which can provide a second
one-way lock configured to releasably inhibit the proximal movement
of the distal articulation driver 10440. The first lock cam 10454
can be rotatably mounted to the distal articulation driver 10440
and can include a projection 10457 rotatably positioned within a
pivot aperture 10447 defined in the distal articulation driver
10440. Similarly, the second lock cam 10456 can be rotatably
mounted to the distal articulation driver 10440 and can include a
projection 10458 rotatably positioned within a pivot aperture 10448
which is also defined in the distal articulation driver 10440. The
articulation lock 10450 can further comprise a frame 10452 having a
lock channel 10451 defined therein which can be configured to
receive at least a portion of the proximal articulation driver
10430, at least a portion of the distal articulation driver 10440,
the first lock cam 10454, and the second lock cam 10456. The lock
channel 10451 can comprise a first lock wall 10453 and a second
lock wall 10459 wherein, when the articulation lock 10450 is in a
locked state, the first lock cam 10454 can be biased into
engagement with the first lock wall 10453 and the second lock cam
10456 can be biased into engagement with the second lock wall
10459. The first lock cam 10454 can be configured to bias a first
bearing point 10445 of the distal articulation driver 10440 against
the second lock wall 10459 when the first lock cam 10454 is in its
locked position. Similarly, the second lock cam 10456 can be
configured to bias a second bearing point 10446 of the distal
articulation driver 10440 against the first lock wall 10453 when
the second lock cam 10454 is in its locked position. Such a locked
state is illustrated in FIG. 119. As also illustrated in FIG. 119,
the articulation lock 10450 can be biased into a locked state by a
spring 10455. The spring 10455 can be configured to rotate the
first lock cam 10454 about its projection 10457 such that a lobe of
the first lock cam 10454 engages the first lock wall 10453 and,
similarly, to rotate the second lock cam 10456 about its projection
10458 such that a lobe of the second lock cam 10456 engages the
second lock wall 10459. In various circumstances, the first lock
cam 10454 and the second lock cam 10456 can each comprise a spring
aperture 10449 defined therein which can be configured to receive
an end of the spring 10455 such that the spring 10455 can apply the
biasing forces discussed above.
[0362] In order to unlock the first lock cam 10454, referring
generally to FIG. 120, the proximal articulation driver 10430 can
be pushed distally such that a distal drive shoulder 10434 of the
proximal articulation driver 10430 contacts the first lock cam
10454 and pushes the first lock cam 10454 distally. In various
circumstances, the first lock cam 10454 can comprise a drive pin
10437 extending therefrom which can be contacted by the distal
drive shoulder 10434 such that, as the proximal articulation driver
10430 is pushed distally, the first lock cam 10454 and the distal
articulation driver 10440 can be slid distally relative to the
first lock surface 10451. In some circumstances, the first lock cam
10454 may rotate about its projection 10447 in order to accommodate
such movement. In any event, similar to the above, the distal
movement of the distal articulation driver 10440 can articulate the
end effector. Once the end effector has been sufficiently
articulated, the proximal articulation driver 10430 can be released
which can permit the biasing spring 10455 to displace the lock cams
10454 and 10456 into engagement with the lock surfaces 10453 and
10459, respectively, and place the articulation lock 10450 in its
locked condition, as illustrated in FIG. 119. In order to unlock
the second lock cam 10456, referring generally to FIG. 121, the
proximal articulation driver 10430 can be pulled proximally such
that a proximal drive shoulder 10436 contacts the second lock cam
10456 and pulls the second lock cam 10456 proximally. In various
circumstances, the second lock cam 10456 can comprise a drive pin
10438 extending therefrom which can be contacted by the proximal
drive shoulder 10436 such that, as the proximal articulation driver
10430 is pulled proximally, the second lock cam 10456 and the
distal articulation driver 10440 can be slid proximally relative to
the second lock surface 10459. In some circumstances, the second
lock cam 10456 may rotate about its projection 10458 in order to
accommodate such movement. In any event, similar to the above, the
proximal movement of the distal articulation driver 10440 can
articulate the end effector in an opposite direction. Similar to
the above, once the end effector has been sufficiently articulated,
the proximal articulation driver 10430 can be released which can
permit the biasing spring 10455 to displace the lock cams 10454 and
10456 into engagement with lock surfaces 10453 and 10459,
respectively, and place the articulation lock 10450 in its locked
condition, as illustrated in FIG. 119.
[0363] Further to the above, when a proximal load P is transmitted
to the distal articulation driver 10440 from the end effector when
the articulation lock 10450 is in its locked condition, the second
lock cam 10456 will be further biased into engagement with the lock
wall 10459. In such circumstances, the proximal load P may only
increase the wedging force holding the second lock cam 10456 in
position. In effect, the second lock cam 10456 can comprise a
one-way lock which can inhibit the proximal movement of the distal
articulation driver 10440 until the second lock cam 10456 is
unlocked, as described above. When the second lock cam 10456 is
unlocked and the distal articulation driver 10440 is being moved
proximally, the first lock cam 10454 may not resist, or at least
substantially resist, the proximal movement of the distal
articulation driver 10440. When a distal load D is transmitted to
the distal articulation driver 10440 from the end effector when the
articulation lock 10450 is in its locked condition, the first lock
cam 10454 will be further biased into engagement with the lock wall
10453. In such circumstances, the distal load D may only increase
the wedging force holding the first lock cam 10454 in position. In
effect, the first lock cam 10454 can comprise a one-way lock which
can inhibit the distal movement of the distal articulation driver
10440 until the first lock cam 10454 is unlocked, as described
above. When the first lock cam 10454 is unlocked and the distal
articulation driver 10440 is being moved distally, the second lock
cam 10454 may not resist, or at least substantially resist, the
distal movement of the distal articulation driver 10440.
[0364] As discussed above, a surgical instrument can comprise a
firing drive for treating tissue captured within an end effector of
the surgical instrument, an articulation drive for articulating the
end effector about an articulation joint, and a clutch assembly
which can be utilized to selectively engage the articulation drive
with the firing drive. An exemplary clutch assembly 10070 was
discussed above while another exemplary clutch assembly, i.e.,
clutch assembly 11070, is discussed below. In various
circumstances, the surgical instruments disclosed herein can
utilize either clutch assembly.
[0365] Turning now to FIGS. 131-149, a surgical instrument can
utilize a shaft assembly 11010 which can include an end effector
10020, an articulation joint 10090, and an articulation lock 10050
which can be configured to releasably hold the end effector 10020
in position. The reader will appreciate that portions of the end
effector 10020 have been removed in FIGS. 131-133 for the purposes
of illustration; however, the end effector 10020 can include a
staple cartridge positioned therein and/or an anvil rotatably
coupled to a channel supporting the staple cartridge. The operation
of the end effector 10020, the articulation joint 10090, and the
articulation lock 10050 was discussed above and is not repeated
herein for sake of brevity. The shaft assembly 11010 can further
include a proximal housing comprised of housing portions 11002 and
11003, for example, which can connect the shaft assembly 11010 to a
handle of a surgical instrument. The shaft assembly 11010 can
further include a closure tube 11015 which can be utilized to close
and/or open the anvil of the end effector 10020. Primarily
referring now to FIGS. 132-134, the shaft assembly 11010 can
include a spine 11004 which can be configured to fixably support
the shaft frame portion 10012, which is discussed above in
connection with articulation lock 10050. The spine 11004 can be
configured to, one, slidably support a firing member 11060 therein
and, two, slidably support the closure tube 11015 which extends
around the spine 11004. The spine 11004 can also be configured to
slidably support a proximal articulation driver 11030. In various
circumstances, the spine 11004 can comprise a proximal end 11009
which is supported by a frame portion 11001 that can be configured
to permit the spine 11004 to be rotated about its longitudinal
axis.
[0366] Further to the above, the shaft assembly 11010 can include a
clutch assembly 11070 which can be configured to selectively and
releasably couple the proximal articulation driver 11030 to the
firing member 11060. The clutch assembly 11070 can comprise a lock
collar, or sleeve, 11072 positioned around the firing member 11060
wherein the lock sleeve 11072 can be rotated between an engaged
position in which the lock sleeve 11072 couples the proximal
articulation driver 11030 to the firing member 11060 and a
disengaged position in which the proximal articulation driver 11030
is not operably coupled to the firing member 11060. When lock
sleeve 11072 is in its engaged position (FIGS. 135, 136, 138, 139,
141, and 145-149), further to the above, distal movement of the
firing member 11060 can move the proximal articulation driver 11030
distally and, correspondingly, proximal movement of the firing
member 11060 can move the proximal articulation driver 11030
proximally. When lock sleeve 11072 is in its disengaged position
(FIGS. 142-144), movement of the firing member 11060 is not
transmitted to the proximal articulation driver 11030 and, as a
result, the firing member 11060 can move independently of the
proximal articulation driver 11030. In various circumstances, the
proximal articulation driver 11030 can be held in position by the
articulation lock 11050 when the proximal articulation driver 11030
is not being moved in the proximal or distal directions by the
firing member 11060.
[0367] Referring primarily to FIG. 134, the lock sleeve 11072 can
comprise a cylindrical, or an at least substantially cylindrical,
body including a longitudinal aperture defined therein configured
to receive the firing member 11060. The lock sleeve 11072 can
comprise a first, inwardly-facing lock member 11073 and a second,
outwardly-facing lock member 11078. The first lock member 11073 can
be configured to be selectively engaged with the firing member
11060. More particularly, when the lock sleeve 11072 is in its
engaged position, the first lock member 11073 can be positioned
within a drive notch 11062 defined in the firing member 11060 such
that a distal pushing force and/or a proximal pulling force can be
transmitted from the firing member 11060 to the lock sleeve 11072.
When the lock sleeve 11072 is in its engaged position, the second
lock member 11078 can be positioned within a drive notch 11035
defined in the proximal articulation driver 11035 such that the
distal pushing force and/or the proximal pulling force applied to
the lock sleeve 11072 can be transmitted to the proximal
articulation driver 11030. In effect, the firing member 11060, the
lock sleeve 11072, and the proximal articulation driver 11030 will
move together when the lock sleeve 11072 is in its engaged
position. On the other hand, when the lock sleeve 11072 is in its
disengaged position, the first lock member 11073 may not be
positioned within the drive notch 11062 of the firing member 11060
and, as a result, a distal pushing force and/or a proximal pulling
force may not be transmitted from the firing member 11060 to the
lock sleeve 11072. Correspondingly, the distal pushing force and/or
the proximal pulling force may not be transmitted to the proximal
articulation driver 11030. In such circumstances, the firing member
11060 can be slid proximally and/or distally relative to the lock
sleeve 11072 and the proximal articulation driver 11030. In order
to accommodate such relative movement, in such circumstances, the
firing member 11060 can include a longitudinal slot or groove 11061
defined therein which can be configured to receive the first lock
member 11073 of the lock sleeve 11072 when the lock sleeve 11072 is
in its disengaged position and, furthermore, accommodate the
longitudinal movement of the firing member 11060 relative to the
lock sleeve 11072. In various circumstances, the second lock member
11078 can remain engaged with the drive notch 11035 in the proximal
articulation driver 11030 regardless of whether the lock sleeve
11072 is in its engaged position or its disengaged position.
[0368] Further to the above, the clutch assembly 11070 can further
comprise a rotatable lock actuator 11074 which can be configured to
rotate the lock sleeve 11072 between its engaged position and its
disengaged position. In various circumstances, the lock actuator
11074 can comprise a collar which can surround the lock sleeve
11072, a longitudinal aperture extending through the collar, and
referring primarily to FIG. 135, an inwardly-extending drive
element 11077 engaged with the lock sleeve 11072. Referring again
to FIG. 134, the lock sleeve 11072 can comprise a longitudinal slot
11079 defined therein within which the drive element 11077 of the
lock actuator 11074 can be received. Similar to the above, the lock
actuator 11074 can be moved between an engaged position in which
the lock actuator 11074 can position the lock sleeve 11072 in its
engaged position and a disengaged position in which the lock
actuator 11074 can position the lock sleeve 11072 in its disengaged
position. In order to move the lock sleeve 11072 between its
engaged position and its disengaged position, the lock actuator
11074 can be rotated about its longitudinal axis such that the
drive element 11077 extending therefrom engages a sidewall of the
slot 11079 to impart a rotational force to the lock sleeve 11072.
In various circumstances, the lock actuator 11074 can be
constrained such that it does not move longitudinally with the lock
sleeve 11072. In such circumstances, the lock actuator 11074 may
rotate within an at least partially circumferential window 11089
defined in the shaft spine 11004. In order to accommodate the
longitudinal movement of the lock sleeve 11072 when the lock sleeve
11072 is in its engaged position, the lock sleeve 11072 can further
include a longitudinal opening 11079 within which the drive element
11077 can travel. In various circumstances, the longitudinal
opening 11079 can include a center notch 11076 which can correspond
with the unarticulated position of the end effector 10020. In such
circumstances, the center notch 11076 can serve as a detent
configured to releasably hold or indicate the centered orientation
of the end effector 10020, for example.
[0369] Further to the above, referring primarily to FIG. 134, the
lock actuator 11074 can further comprise a cam follower 11081
extending outwardly therefrom which can be configured to receive a
force applied thereto in order to rotate the lock sleeve 11072 as
described above. In various circumstances, the shaft assembly 11010
can further comprise a switch drum 11075 which can be configured to
apply a rotational force to the cam follower 11081. The switch drum
11075 can extend around the lock actuator 11074 and include a
longitudinal slot 11083 defined therein within which the cam
follower 11081 can be disposed. When the switch drum 11075 is
rotated, a sidewall of the slot 11083 can contact the cam follower
11081 and rotate the lock actuator 11074, as outlined above. The
switch drum 11075 can further comprise at least partially
circumferential openings 11085 defined therein which, referring to
FIG. 137, can be configured to receive circumferential mounts 11007
extending from the shaft housing comprising housing halves 11002
and 11003 and permit relative rotation, but not translation,
between the switch drum 11075 and the shaft housing. Referring
again to FIG. 134, the switch drum 11075 can be utilized to rotate
the lock actuator 11074 and the lock sleeve 11072 between their
engaged and disengage positions. In various circumstances, the
shaft assembly 11010 can further comprise a biasing member, such as
spring 11080, for example, which can be configured to bias the
switch drum 11075 in a direction which biases the lock actuator
11074 and the lock sleeve 11072 into their engaged positions. Thus,
in essence, the spring 11080 and the switch drum 11075 can be
configured to bias the articulation drive system into operative
engagement with the firing drive system. As also illustrated in
FIG. 134, the switch drum 11075 can comprise portions of a slip
ring assembly 11005 which can be configured to conduct electrical
power to and/or from the end effector 10020 and/or communicate
signals to and/or from the end effector 10020. The slip ring
assembly 11005 can comprise a plurality of concentric, or at least
substantially concentric, conductors 11008 on opposing sides
thereof which can be configured to permit relative rotation between
the halves of the slip ring assembly 11005 while still maintaining
electrically conductive pathways therebetween. U.S. patent
application Ser. No. 13/800,067, entitled STAPLE CARTRIDGE TISSUE
THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, is incorporated by
reference in its entirety. U.S. patent application Ser. No.
13/800,025, entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR
SYSTEM, filed on Mar. 13, 2013, is incorporated by reference in its
entirety.
[0370] In various circumstances, further to the above, the closure
mechanism of the shaft assembly 11010 can be configured to bias the
clutch assembly 11070 into its disengaged state. For instance,
referring primarily to FIGS. 134 and 144-147, the closure tube
11015 can be advanced distally to close the anvil of the end
effector 10020, as discussed above and, in doing so, cam the lock
actuator 11074 and, correspondingly, the lock sleeve 11072, into
their disengaged positions. To this end, the closure tube 11015 can
comprise a cam window 11016, through which the cam follower 11081
extending from the lock actuator 11074 can extend. The cam window
11016 can include an angled sidewall, or cam edge, 11017 which can
be configured to engage the cam follower 11081 as the closure tube
11015 is moved distally between an open, or unclosed, position
(FIGS. 145-149) to a closed position (FIGS. 142-144) and rotate the
lock actuator 11074 from its engaged position (FIGS. 145-149) to
its disengaged position (FIGS. 142-144). Upon comparing FIGS. 144
and 149, the reader will appreciate that, when the cam follower
11081 and the lock actuator 11074 are cammed into their disengaged
position, the cam follower 11081 can rotate the switch drum 11075
and compress the spring 11080 between the switch drum 11075 and the
shaft housing. As long as the closure tube 11015 remains in its
advanced, closed position, the articulation drive will be
disconnected from the firing drive. In order to re-engage the
articulation drive with the firing drive, the closure tube 11015
can be retracted into its unactuated position, which can also open
the end effector 10020, and can, as a result, pull the cam edge
11017 proximally and permit the spring 11080 to re-bias the lock
actuator 11074 and the lock sleeve 11072 into their engaged
positions.
[0371] As described elsewhere in greater detail, the surgical
instrument 1010 may include several operable systems that extend,
at least partially, through the shaft 1210 and are in operable
engagement with the end effector 1300. For example, the surgical
instrument 1010 may include a closure assembly that may transition
the end effector 1300 between an open configuration and a closed
configuration, an articulation assembly that may articulate the end
effector 1300 relative to the shaft 1210, and/or a firing assembly
that may fasten and/or cut tissue captured by the end effector
1300. In addition, the surgical instrument 1010 may include a
housing such as, for example, the handle 1042 which may be
separably couplable to the shaft 1210 and may include complimenting
closure, articulation, and/or firing drive systems that can be
operably coupled to the closure, articulation, and firing
assemblies, respectively, of the shaft 1210 when the handle 1042 is
coupled to the shaft 1210.
[0372] In use, an operator of the surgical instrument 1010 may
desire to reset the surgical instrument 1010 and return one or more
of the assemblies of the surgical instrument 1010 to a default
position. For example, the operator may insert the end effector
1300 into a surgical site within a patient through an access port
and may then articulate and/or close the end effector 1300 to
capture tissue within the cavity. The operator may then choose to
undo some or all of the previous actions and may choose to remove
the surgical instrument 1010 from the cavity. The surgical
instrument 1010 may include one more systems configured to
facilitate a reliable return of one or more of the assemblies
described above to a home state with minimal input from the
operator thereby allowing the operator to remove the surgical
instrument from the cavity.
[0373] Referring to FIG. 150, the surgical instrument 1010 may
include an articulation control system 3000. A surgical operator
may utilize the articulation control system 3000 to articulate the
end effector 1300 relative to the shaft 1210 between an
articulation home state position and an articulated position. In
addition, the surgical operator may utilize the articulation
control system 3000 to reset or return the articulated end effector
1300 to the articulation home state position. The articulation
control system 3000 can be positioned, at least partially, in the
handle 1042. In addition, as illustrated in the exemplary schematic
block diagram in FIG. 151, the articulation control system 3000 may
comprise a controller such as, for example, controller 3002 which
can be configured to receive an input signal and, in response,
activate a motor such as, for example, motor 1102 to cause the end
effector 1300 to articulate in accordance with such an input
signal. Examples of suitable controllers are described elsewhere in
this document and include but are not limited to microcontroller
7004 (See FIG. 185).
[0374] Further to the above, the end effector 1300 can be
positioned in sufficient alignment with the shaft 1210 in the
articulation home state position, also referred to herein as an
unarticulated position such that the end effector 1300 and at least
a portion of shaft 1210 can be inserted into or retracted from a
patient's internal cavity through an access port such as, for
example, a trocar positioned in a wall of the internal cavity
without damaging the axis port. In certain embodiments, the end
effector 1300 can be aligned, or at least substantially aligned,
with a longitudinal axis "LL" passing through the shaft 1210 when
the end effector 1300 is in the articulation home state position,
as illustrated in FIG. 150. In at least one embodiment, the
articulation home state position can be at any angle up to and
including 5.degree., for example, with the longitudinal axis on
either side of the longitudinal axis. In another embodiment, the
articulation home state position can be at any angle up to and
including 3.degree., for example, with the longitudinal axis on
either side of the longitudinal axis. In yet another embodiment,
the articulation home state position can be at any angle up to and
including 7.degree., for example, with the longitudinal axis on
either side of the longitudinal axis.
[0375] The articulation control system 3000 can be operated to
articulate the end effector 1300 relative to the shaft 1210 in a
plane intersecting the longitudinal axis in a first direction such
as, for example, a clockwise direction and/or a second direction
opposite the first direction such as, for example, a
counterclockwise direction. In at least one instance, the
articulation control system 3000 can be operated to articulate the
end effector 1300 in the clockwise direction form the articulation
home state position to an articulated position at a 10.degree.
angle with the longitudinal axis on the right to the longitudinal
axis, for example. In another example, the articulation control
system 3000 can be operated to articulate the end effector 1300 in
the counterclockwise direction form the articulated position at the
10.degree. angle with the longitudinal axis to the articulation
home state position. In yet another example, the articulation
control system 3000 can be operated to articulate the end effector
1300 relative to the shaft 1210 in the counterclockwise direction
from the articulation home state position to an articulated
position at a 10.degree. angle with the longitudinal axis on the
left of the longitudinal axis. The reader will appreciate that the
end effector can be articulated to different angles in the
clockwise direction and/or the counterclockwise direction in
response to the operator's commands.
[0376] Referring to FIG. 150, the handle 1042 of the surgical
instrument 1010 may comprise an interface 3001 which may include a
plurality of inputs that can be utilized by the operator, in part,
to articulate the end effector 1300 relative to the shaft 1210, as
described above. In certain embodiments, the interface 3001 may
comprise a plurality of switches which can be coupled to the
controller 3002 via electrical circuits, for example. In the
embodiment illustrated in FIG. 151, the interface 3001 comprises
three switches 3004A-C, wherein each of the switches 3004A-C is
coupled to the controller 3002 via one of three electrical circuits
3006A-C, respectively. The reader will appreciate that other
combinations of switches and circuits can be utilized with the
interface 3001.
[0377] Further to the above, the controller 3002 may comprise a
processor 3008 and/or one or more memory units 3010. By executing
instruction code stored in the memory 3010, the processor 3008 may
control various components of the surgical instrument 1, such as
the motor 1102 and/or a user display. The controller 3002 may be
implemented using integrated and/or discrete hardware elements,
software elements, and/or a combination of both. Examples of
integrated hardware elements may include processors,
microprocessors, microcontrollers, integrated circuits, application
specific integrated circuits (ASIC), programmable logic devices
(PLD), digital signal processors (DSP), field programmable gate
arrays (FPGA), logic gates, registers, semiconductor devices,
chips, microchips, chip sets, microcontroller, system-on-chip
(SoC), and/or system-in-package (SIP). Examples of discrete
hardware elements may include circuits and/or circuit elements
(e.g., logic gates, field effect transistors, bipolar transistors,
resistors, capacitors, inductors, relay and so forth). In other
embodiments, the controller 3002 may include a hybrid circuit
comprising discrete and integrated circuit elements or components
on one or more substrates, for example.
[0378] Referring again to FIG. 151, the surgical instrument 1010
may include a motor controller 3005 in operable communication with
the controller 3002. The motor controller 3005 can be configured to
control a direction of rotation of the motor 1102. For example, the
motor 1102 can be powered by a battery such as, for example, the
battery 1104 and the motor controller 3002 may be configured to
determine the voltage polarity applied to the motor 1102 by the
battery 1104 and, in turn, the direction of rotation of the motor
1102 based on input from the controller 3002. For example, the
motor 1102 may reverse the direction of its rotation from a
clockwise direction to a counterclockwise direction when the
voltage polarity applied to the motor 1102 by the battery 1104 is
reversed by the motor controller 3005 based on input from the
controller 3002. Examples of suitable motor controllers are
described elsewhere in this document and include but are not
limited to the driver 7010 (FIG. 185).
[0379] In addition, as described elsewhere in this document in
greater detail, the motor 1102 can be operably coupled to an
articulation drive such as, for example, the proximal articulation
drive 10030 (FIG. 37). In use, the motor 1102 can drive the
proximal articulation drive 10030 distally or proximally depending
on the direction in which the motor 1102 rotates. Furthermore, the
proximal articulation drive 10030 can be operably coupled to the
end effector 1300 such that, for example, the axial translation of
the proximal articulation drive 10030 proximally may cause the end
effector 1300 to be articulated in the counterclockwise direction,
for example, and/or the axial translation of the proximal
articulation drive 10030 distally may cause the end effector 1300
to be articulated in the clockwise direction, for example.
[0380] Further to the above, referring again to FIG. 151, the
interface 3001 can be configured such that the switch 3004A can be
dedicated to clockwise articulation of the end effector 1300 and
the switch 3004B can be dedicated to counterclockwise articulation
of the end effector 1300. For example, the operator may articulate
the end effector 1300 in the clockwise direction by closing the
switch 3004A which may signal the controller 3002 to cause the
motor 1102 to rotate in the clockwise direction thereby, as a
result, causing the proximal articulation drive 10030 to be
advanced distally and causing the end effector 1300 to be
articulated in the clockwise direction. In another example, the
operator may articulate the end effector 1300 in the
counterclockwise direction by closing the switch 3004B which may
signal the controller 3002 to cause the motor 1102 to rotate in the
counterclockwise direction, for example, and retracting the
proximal articulation drive 10030 proximally to articulate the end
effector 1300 to in the counterclockwise direction.
[0381] Further to the above, the switches 3004A-C can comprise
open-biased dome switches, as illustrated in FIG. 154. Other types
of switches can also be employed such as, for example, capacitive
switches. In the embodiment illustrated in FIG. 154, the dome
switches 3004A and 3004B are controlled by a rocker 3012. Other
means for controlling the switches 3004A and 3004B are also
contemplated within the scope of the present disclosure. In the
neutral position, illustrated in FIG. 154, both of the switches
3004A and 3004B are biased in the open position. The operator, for
example, may articulate the end effector 1300 in the clockwise
direction by tilting the rocker forward thereby depressing the dome
switch 3004A, as illustrated in FIG. 155. In result, the circuit
3006A (FIG. 151) may be closed signaling the controller 3002 to
activate the motor 1102 to articulate the end effector 1300 in the
clockwise direction, as described above. The motor 1102 may
continue to articulate the end effector 1300 until the operator
releases the rocker 3012 thereby allowing the dome switch 3004A to
return to the open position and the rocker 3012 to the neutral
position. In some circumstances, the controller 3002 may be able to
identify when the end effector 1300 has reached a predetermined
maximum degree of articulation and, at such point, interrupt power
to the motor 1102 regardless of whether the dome switch 3004A is
being depressed. In a way, the controller 3002 can be configured to
override the operator's input and stop the motor 1102 when a
maximum degree of safe articulation is reached. Alternatively, the
operator may articulate the end effector 1300 in the
counterclockwise direction by tilting the rocker back thereby
depressing the dome switch 3004B, for example. In result, the
circuit 3006B may be closed signaling the controller 3002 to
activate the motor 1102 to articulate the end effector 1300 in the
counterclockwise direction, as described above. The motor 1102 may
continue to articulate the end effector 1300 until the operator
releases the rocker 3012 thereby allowing the dome switch 3004B to
return to the open position and the rocker 3012 to the neutral
position. In some circumstances, the controller 3002 may be able to
identify when the end effector 1300 has reached a predetermined
maximum degree of articulation and, at such point, interrupt power
to the motor 1102 regardless of whether the dome switch 3004B is
being depressed. In a way, the controller 3002 can be configured to
override the operator's input and stop the motor 1102 when a
maximum degree of safe articulation is reached.
[0382] In certain embodiments, the articulation control system 3000
may include a virtual detent that may alert the operator when the
end effector reaches the articulation home state position. For
example, the operator may tilt the rocker 3012 to articulate the
end effector 1300 from an articulated position to the articulation
home state position. Upon reach the articulation home state
position, the controller 3002 may stop the articulation of the end
effector 1300. In order to continue past the articulation home
state position, the operator may release the rocker 3012 and then
tilt it again to restart the articulation. Alternatively, a
mechanical detent can also be used to provide haptic feedback for
the operator that the end effect reached the articulation home
state position. Other forms of feedback may be utilized such as
audio feedback, for example.
[0383] Further to the above, the articulation control system 3000
may include a reset input which may reset or return the end
effector 1300 to the articulation home state position if the end
effector 1300 is in an articulated position. For example, as
illustrated in FIG. 160, upon receiving a reset input signal, the
controller 3002 may determine the articulation position of the end
effector 1300 and, if the end effector 1300 is in the articulation
home state position, the controller 3002 may take no action.
However, if the end effector 1300 is in an articulated position
when it receives a reset input signal, the controller may activate
the motor 1102 to return the end effector 1300 to the articulation
home state position. As illustrated in FIG. 156, the operator may
depress the rocker 3012 downward to close the dome switches 3004A
and 3004B simultaneously, or at least within a short time period
from each other, which may transmit the reset input signal to the
controller 3002 to reset or return the end effector 1300 to the
articulation home state position. The operator may then release the
rocker 3012 thereby allowing the rocker 3012 to return to the
neutral position and the switches 3004A and 3004B to the open
positions. Alternatively, the interface 3001 of articulation
control system 3000 may include a separate reset switch such as,
for example, another dome switch which can be independently closed
by the operator to transmit the reset input signal to the
controller 3002.
[0384] Referring to FIGS. 157-159, in certain embodiments, the
interface 3001 of the surgical instrument 1010 may include an
interface rocker 3012A which may include a contact member 3013
which can be configured to assist the rocker 3012A into its neutral
position, as illustrated in FIG. 157. The contact member 3013 can
comprise an arcuate surface 3017 which can be biased against the
interface housing 3011 by a biasing member and/or by biasing forces
applied thereto by the dome switches 3004A and 3004B. The contact
member 3013 may be configured to rock, or rotate, when the operator
tilts the rocker 3012A forward, as illustrated in FIG. 158, or back
in order to articulate the end effector 1300 in the clockwise
direction or the counterclockwise direction, respectively. When the
rocker 3012A is released, the arcuate surface of the rocker 3012A
can be rotated back into its neutral position against the interface
housing 3011 by the biasing forces applied thereto. In various
circumstances, the contact member 3013 may be displaced away from
the interface housing 3011 when the operator depresses the rocker
3012A downwardly, as illustrated in FIG. 159, to depress the dome
switches 3004A and 3004B simultaneously, or at least within a short
time period from each other, which may transmit the reset input
signal to the controller 3002 to reset or return the end effector
1300 to the articulation home state position, as discussed
above.
[0385] As described above, the controller 3002 can be configured to
determine the articulation position of the end effector 1300.
Knowledge of the articulation position of the end effector 1300 may
allow the controller 3002 to determine whether the motor 1102 needs
to be activated to return the end effector 1300 to the articulation
home state position and, if so, to determine the direction of
rotation, and the amount of the rotation, of the motor 1102
required to return the end effector 1300 to the articulation home
state position. In certain embodiments, the controller 3002 may
track the articulation of the end effector 1300 and store the
articulation position of the end effector 1300, for example, in the
memory 3010. For example, the controller 3002 may track the
direction of rotation, speed of rotation, and the time of rotation
of the motor 1102 when the motor 1102 is used to articulate the end
effector 1300. In some circumstances, the controller 3002 can be
configured to evaluate the displacement of the firing system when
the firing system is used to drive the articulation system. More
specifically, when the articulation drive is coupled to the firing
drive, the controller 3002 can monitor the firing drive in order to
determine the displacement of the articulation drive. The processor
3008 may calculate the articulation position of the end effector
1300 based on these parameters and store the displaced position of
the articulation drive in the memory 3010, for example. The reader
will appreciate that other parameters can be tracked and other
algorithms can be utilized by the processor 3010 to calculate the
articulation position of the end effector 1300, all of which are
contemplated by the present disclosure. The stored articulation
position of the end effector 1300 can be continuously updated as
the end effector 1300 is articulated. Alternatively, the stored
articulation position can be updated at discrete points, for
example, when the operator releases the dome switch 3004A or the
switch 3004B after depressing the same to articulate the end
effector 1300.
[0386] In any event, upon receiving the reset input signal, the
processor 3008 may access the memory 3010 to recover the last
stored articulation position of the end effector 1300. If the last
stored articulation position is not the articulation home state
position, the processor 3008 may calculate the direction and time
of rotation of the motor 1102 required to return the end effector
1300 to the articulation home state position based on the last
stored articulation position. In some circumstances, the processor
3008 may calculate the distance and direction in which the firing
drive needs to be displaced in order to place the articulation
drive in its home state position. In either event, the controller
3002 may activate the motor 1102 to rotate accordingly to return
the end effector 1300 to the articulation home state position.
Furthermore, the processor 3008 may also update the stored
articulation position to indicate articulation home state position.
However, if the last stored articulation position is the
articulation home state position, the controller 3002 may take no
action. In some circumstances, the controller 3002 may alert the
user through some form of feedback that the end effector and the
articulation system is in its home state position. For example, the
controller 3002 can be configured to activate a sound and/or a
light signal to alert the operator that the end effector 1300 is in
the articulation home state position.
[0387] In certain embodiments, the surgical instrument 1010 may
include a sensor configured to detect the articulation position of
the end effector 1300 and communicate the same to the controller
3002. Similar to the above, the detected articulation position of
the end effector 1300 can be stored in the memory 3010 and can be
continuously updated as the end effector 1300 is articulated or can
be updated when the operator releases the dome switch 3004A or
after depressing the same to articulate the end effector 1300, for
example.
[0388] In certain embodiments, it may be desirable to include a
warning step prior to resetting or returning the end effector 1300
to the articulation home state position to allow an operator a
chance to remedy an erroneous activation of the reset switch. For
example, the controller 3002 can be configured to react to a first
transmission of the reset input signal to the controller 3002 by
activating a light and/or a sound signal alerting the operator that
the rocker 3012 has been depressed. In addition, the controller
3002 can also be configured to react to a second transmission of
the reset input signal to the controller 3002 within a
predetermined time period from the first transmission by activating
the motor 1102 to return the end effector 1300 to the articulation
home state position. Said another way, a first downward depression
of the rocker 3012 may yield a warning to the operator and a second
downward depression of the rocker 3012 within a predetermined time
period from the first downward depression may cause the controller
3002 to activate the motor 1102 to return the end effector 1300 to
the articulation home state position.
[0389] Further to the above, the interface 3001 may include a
display which can be used by the controller 3002 to communicate a
warning message to the operator in response to the first downward
depression of the rocker 3012. For example, in response to the
first downward depression of the rocker 3012, the controller 3002
may prompt the operator through the display to confirm that the
operator wishes to return the end effector 1300 to the articulation
home state position. If the operator responds by depressing the
rocker 3012 a second time within the predetermined period of time,
the controller 3012 may react by activating the motor 1102 to
return the end effector 1300 to the articulation home state
position.
[0390] As described elsewhere in greater detail, the end effector
1300 of the surgical instrument 1010 may include a first jaw
comprising an anvil such as, for example, the anvil 1310 and a
second jaw comprising a channel configured to receive a staple
cartridge such as, for example, the staple cartridge 1304 which may
include a plurality of staples. In addition, the end effector 1300
can be transitioned between an open configuration and a closed
configuration. Furthermore, the surgical instrument 1010 may
include a closure lock and the handle 1042 may include a release
member for the closure lock such as, for example, the release
member 1072 which can be depressed by the operator to release the
closure lock thereby returning the end effector 1300 to the open
configuration. In addition, the controller 3002 can be coupled to a
sensor 3014 configured to detect the release of the closure lock by
the release member 1272. Furthermore, the surgical instrument 1010
may include a firing drive such as, for example, the firing drive
1110 which can be operably coupled to a firing member such as, for
example, the firing member 10060. The controller 3002 can be
coupled to a sensor 3015 configured to detect the position of the
firing drive 1110. The firing drive 1110 can be moved axially to
advance the firing member 10060 from a firing home state position
to a fired position to deploy the staples from the staple cartridge
1304 and/or cut tissue captured between the anvil 1310 and the
staple cartridge 1304 when the end effector 1300 is in the closed
configuration.
[0391] Also, as described elsewhere in greater detail, the proximal
articulation drive 10030 of the surgical instrument 1010 can be
selectively coupled with the firing drive 1110 such that, when the
firing drive 1110 is motivated by the motor 1102, the proximal
articulation drive 10030 can be driven by the firing drive 1110 and
the proximal articulation drive 10030 can, in turn, articulate the
end effector 1300 relative to the shaft 1210, as described above.
Furthermore, the firing drive 1110 can be decoupled from the
proximal articulation drive 10030 when the end effector 1300 is in
the closed configuration. This arrangement permits the motor 1102
to motivate the firing drive 1110 to move the firing member 10060
between the firing home state position and the fired position
independent of the proximal articulation drive 10030.
[0392] Further to the above, as described else wherein in greater
detail, the surgical instrument 1010 can include a clutch system
10070 (See FIG. 37) which can be engaged when the end effector 1300
is transitioned from the open configuration to the closed
configuration and disengaged when the end effector 1300 is
transitioned from the closed configuration to the open
configuration. When engaged, the clutch system 10070 may operably
couple the firing drive 1110 to the proximal drive member 10030 and
when the clutch member is disengaged, the firing drive 1110 may be
decoupled from the proximal articulation drive. Since the firing
drive 1110 can be decoupled and moved independently from the
proximal articulation drive 10030, the controller 3002 may be
configured to guide the firing drive 1110 to locate the proximal
articulation drive 10030 and re-couple the proximal articulation
drive 10030 to the firing drive 1110 once again. The controller
3002 may track the direction of rotation, speed of rotation and the
time of rotation of the motor 1102 when the firing drive 1110 is
coupled to the proximal articulation drive 10030 to determine and
store the location of the proximal articulation drive 10030, for
example, in memory 3010. The controller 3002 may, as described
elsewhere herein, monitor the displacement of the firing system
used to drive the articulation system. Other parameters and
algorithms can be utilized to determine the location of the
proximal articulation drive 10030. In certain embodiments, the
firing drive 1110 may include a sensor configured to detect when
the firing drive 1110 is coupled to the proximal articulation drive
10030 and communicate the same to the controller 3002 to confirm
the coupling engagement between the firing drive 1110 and the
proximal articulation drive 10030. In certain embodiments, when the
controller 3002 is not configured to store and access the
articulation position of the end effector 1300, the controller may
activate the motor 1102 to motivate the firing drive 1110 to travel
along its full range of motion until the firing drive 1110 comes
into coupling arrangement with the proximal articulation drive
10030.
[0393] Further to the above, in certain embodiments, the firing
home state position of the firing member 10060 can be located at a
proximal portion of the end effector 1300. Alternatively, the
firing home state position of the firing member 10060 can be
located at a distal portion of the end effector 1300. In certain
embodiments, the firing home state position may be defined at a
position where the firing member 10060 is sufficiently retracted
relative to the end effector 1300 such that the end effector 1300
can be freely moved between the open configuration and the closed
configuration. In other circumstances, the firing home state
position of the firing member 10060 can be identified as the
position of the firing member which positions the articulation
drive system and the end effector in its articulated home state
position.
[0394] Referring again to FIG. 151, the interface 3001 of the
surgical instrument 1010 may include a home state input. The
operator may utilize the home state input to transmit a home state
input signal to the controller 3002 to return the surgical
instrument 1010 to home state which may include returning the end
effector 1300 to the articulation home state position and/or the
firing member 10060 to the firing home state position. As
illustrated in FIG. 154, the home state input may include a switch
such as, for example, the switch 3004C which can be coupled to the
controller 3002 via an electrical circuit 3006C. As illustrated in
FIGS. 152 and 153, the home state input may include a cap or a
cover such as, for example, cover 3014 which can be depressed by
the operator to close the switch 3004C and transmit the home state
input signal through the circuit 3006C to the controller 3002.
[0395] Referring again to FIG. 161, the controller 3002, upon
receiving the home state input signal, may check the position of
the firing drive 1110 through the sensor 3015 and may check the
memory 3010 for the last updated articulation position. If the
controller 3002 determines that the end effector 1300 is in the
articulation home state position and the firing drive 1110 is
positioned such that it is coupled to the proximal articulation
drive 10030, the controller 3002 may take no action. Alternatively,
the controller 3002 may provide feedback to the operator that the
surgical instrument 1010 is at home state. For example, the
controller 3002 can be configured to activate a sound and/or a
light signal or transmit a message through the display to alert the
operator that the surgical instrument 1010 is at home state.
However, if the controller 3002 determines that the end effector
1300 is not in the articulation home state position and the firing
drive 1110 is positioned such that it is coupled to the proximal
articulation drive 10030, the controller 3002 may activate the
motor 1102 to motivate the firing drive 1110 to move the proximal
articulation drive 10030 which can, in turn, articulate the end
effector 1300 relative to the shaft 1210 back to the articulation
home state position. Alternatively, if the controller 3002
determines that the end effector 1300 is in the articulation home
state position but the firing drive 1110 is not positioned such
that it is coupled to the proximal articulation drive 10030, the
controller 3002 may activate the motor 1102 to move the firing
drive 1110 to a position wherein the firing drive 1110 is coupled
to the articulation drive 10030. In doing so, the motor 1102 may
retract the firing member 10060 to the firing home state
position.
[0396] In certain embodiments, referring to FIG. 162, the
controller 3002, upon receiving the home state input signal, may
check whether the end effector 1300 is in the open configuration
through the sensor 3016. Other means for determining whether the
end effector 1300 is in the open configuration can be employed. If
the controller 3002 determines that the end effector 1300 is in the
open configuration, the controller 3002 may proceed as described
above. However, if the controller 3002, upon receiving the home
state input signal, determines that the end effector 1300 is in the
closed configuration, the controller 3002 may prompt the operator
to confirm that the operator wishes to return the surgical
instrument 1010 to home state. This step can be a precautionary
step to prevent the operator from accidentally opening the end
effector 1300 during a surgical procedure, for example. In certain
embodiments, the controller 3002 may prompt the operator by
displaying a message on a display coupled to the controller 3002,
for example, requesting the operator to return the end effector
1300 to the open configuration by depressing the release member
1072. If the operator does not release the end effector 1300 to the
open configuration, the controller 3002 may take no action. In
other embodiments, the controller 3002 may alert the operator by
displaying an error message or activating a sound or a light.
However, if the operator releases the end effector 1300 to the open
configuration, the controller 3002 may reset the surgical
instrument as described above.
[0397] Referring to FIG. 163, the firing member 10060 may comprise
a separate firing reset input which may include a switch and an
electrical circuit coupling the switch to controller 3002, wherein
the switch can be configured to close the circuit and transmit a
firing reset input signal to the controller 3002. The controller
3002, upon receiving the firing reset input signal may check
whether the firing member 10060 is in the firing home state
position. As described elsewhere in greater detail, the firing
member 10060 may be operably coupled to the firing drive 1110 which
may comprise a sensor such as, for example, sensor 3015 (See FIG.
151) that may transmit the location of the firing drive 1110 to the
controller 3002. Accordingly, the controller 3002 can determine the
location of the firing member 10060 by monitoring the location of
the firing drive 1110. In any event, if the controller 3002
determines that the firing member 10060 is in the firing home state
position, the controller may take no action or may alert the
operator that the firing member 10060 is already in the firing home
state position by activating a sound and/or a light. On the hand,
if the controller 3002 determines that the firing member 10060 is
not in the firing home state position, the controller 3002 may
activate the motor 1102 to motivate the firing drive 1110 to return
the firing member 10060 to the firing home state position.
[0398] As described elsewhere in greater detail, the surgical
instrument 1010 may include several assemblies that extend, at
least partially, through the shaft 1210 and may be in operable
engagement with the end effector 1300. For example, the surgical
instrument 1010 may include a closure assembly that may transition
the end effector 1300 between an open configuration and a closed
configuration, an articulation assembly that may articulate the end
effector 1300 relative to the shaft 1210, and/or a firing assembly
that may fasten and/or cut tissue captured by the end effector
1300. In addition, the surgical instrument 1010 may include a
housing such as, for example, the handle 1042 which may be
separably couplable to the shaft 1210 and may include complimenting
closure, articulation, and/or firing drive systems that can be
operably coupled to the closure, articulation, and/or firing
assemblies, respectively, of the shaft 1210 when the handle 1042 is
coupled to the shaft 1210.
[0399] In use, the assemblies described above and their
corresponding drive systems may be operably connected. Attempting
to separate the handle 1042 from the shaft 1210 during operation of
the surgical instrument 1010 may sever the connections between the
assemblies and their corresponding drive systems in a manner that
may cause one or more of these assemblies and their corresponding
drive systems to be out of alignment. On the other hand, preventing
the user from separating the handle 1042 from the shaft 1210 during
operation, without more, may lead to confusion, frustration, and/or
an erroneous assumption that the surgical instrument is not
operating properly.
[0400] The surgical instrument 1010 may include a safe release
system 3080 that may be configured to return one or more of the
assemblies and/or corresponding drive systems of the surgical
instrument 1010 to a home state thereby allowing the operator to
safely separate the handle 1042 from the shaft 1210. The term home
state as used herein may refer to a default state wherein one or
more of the assemblies and/or corresponding drive systems of the
surgical instrument 1010 may reside or may be returned to their
default position such as, for example, their position prior to
coupling the handle 1042 with the shaft 1210.
[0401] Referring to FIG. 150, the safe release system 3080 of the
surgical instrument 1010 may include a locking member such as, for
example, locking member 3082 which can be moved between a locked
configuration and an unlocked configuration. As illustrated in FIG.
164 and as described elsewhere in greater detail, the shaft 1210
may be aligned and coupled with the handle 1042 of the surgical
instrument 1010. In addition, the locking member 3082 may be moved
from the unlocked configuration to the locked configuration to lock
the handle in coupling engagement with the shaft 1210. The locking
member 3082 can be positioned at a proximal portion of the shaft
1210, as illustrated in FIG. 166 and may include a latch member
3083 that can be advanced into a receiving slot 3085 positioned in
the handle 1042 when the locking member 3082 is moved to the locked
configuration and the handle 1042 is coupled to the shaft 1210. In
addition, the latch member 3083 can be retracted out of the
receiving slot 3085 when the locking member 3082 is moved to the
unlocked configuration thereby allowing the handle 1042 to be
separated from the shaft 1210, as illustrated in FIG. 167.
[0402] Referring to FIG. 151, the safe release system 3080 may
further include an interlock switch 3084 which can be coupled to
the controller 3002 via an electric circuit 3086 which can be
configured to transmit a home state input signal to the controller
3002. In addition, the interlock switch 3084 may be operably
coupled to the locking member 3082. For example, the switch 3086
can be moved to close the circuit 3086 when the locking member is
moved to the unlocked configuration, as illustrated in FIG. 167 and
can be moved to open the circuit 3086 when the locking member 3082
is moved to the locked configuration, as illustrated in FIG. 166.
In this example, the controller 3002 can be configured to recognize
the closing of the circuit 3086 as a transmission of the home state
input signal. Alternatively, in another example, the switch 3086
can be moved to open the circuit 3086 when the locking member is
moved to the unlocked configuration and can be moved to close the
circuit 3086 when the locking member 3082 is moved to the locked
configuration. In this example, the controller 3002 can be
configured to recognize the opening of the circuit 3086 as a
transmission of the home state input signal.
[0403] Referring again to FIG. 166 and FIG. 167, the locking member
3082 may include a first surface 3090 and a second surface 3092
which can be separated by a ramp 3094, wherein the locking member
3082 can be positioned relative to the switch 3084 such that the
first surface 3090 and the second 3092 may be slidably movable
relative to the switch 3084 when the handle 1042 is coupled to the
shaft 1210. Furthermore, as illustrated in FIG. 166, the first
surface 3090 may extend in a first plane and the second surface
3092 may extend in a second plane, wherein the switch 3084 can be
closer to the first plane that the second plane. Furthermore, as
illustrated in FIG. 166, the switch 3084 may be depressed by the
first surface 3090 when the locking member 3082 is in the locked
configuration and the latch member 3083 is received within the
receiving slot 3085, thereby closing the circuit 3086 (FIG. 151)
and transmitting the home state input signal to the controller
3002. However, as the locking member 3082 is moved to the unlocked
configuration and the latch member 3083 is retracted from the
receiving slot 3085, the switch 3084 may slide along the ramp 3094
to face the second surface 3092 which may provide the biased switch
3084 with sufficient room to return to the open position, as
illustrated in FIG. 166.
[0404] In certain embodiments, as illustrated in FIGS. 151 and 165,
a first end 3084a of the switch 3084 can be positioned in the
handle 1042, for example, at a distal portion thereof and a second
end 3084b of the switch 3084 can be positioned in the shaft 1210,
for example, at a proximal portion thereof and can be operably
coupled with the locking member 3082. In these embodiments, the
switch 3084 may not close the circuit 3086 until the handle 1042 is
coupled to the shaft 1210 to permit the locking member 3082 to
bring the second end 3084b of the switch 3084 into contact with the
first end 3084a thereby closing the circuit 3086 and transmitting
the home state input signal to the controller 3002. In other
embodiments, the locking member 3082, the first end 3084a, and the
second end 3084b of the switch 3084 can be placed in the handle
1042 to permit closure of the circuit 3086 and transmission of the
home state input signal to the controller 3002 prior to coupling
the handle 1042, for example, to return the firing drive system to
its default position to ensure proper alignment with the firing
assembly when the shaft 1210 is coupled to the handle 1042.
[0405] As described elsewhere in greater detail, the end effector
1300 of the surgical instrument 1010 may include a first jaw
comprising an anvil such as, for example, the anvil 1310 and a
second jaw comprising a channel configured to receive a staple
cartridge such as, for example, the staple cartridge 1304 which may
include a plurality of staples. In addition, the end effector 1300
can be transitioned between an open configuration and a closed
configuration. For example, the surgical instrument 1010 may
include a closure lock for locking the end effector 1300 in a
closed configuration and the handle 1042 may include a release
member for the closure lock such as, for example, the release
member 1072 which can be depressed by the operator to release the
closure lock thereby returning the end effector 1300 to the open
configuration. In addition, the controller 3002 can be coupled to a
sensor 3014 configured to detect the release of the closure lock by
the release member 1072. Furthermore, the surgical instrument 1010
may include a firing drive such as, for example, the firing drive
1110 which can be operably coupled to a firing member such as, for
example, the firing member 10060. The controller 3002 can be
coupled to a sensor 3015 configured to detect the position of the
firing drive 1110. In addition, the firing drive 1110 can be
advanced axially, as illustrated in FIG. 167A, to advance the
firing member 10060 between an unfired position and a fired
position to deploy the staples of the staple cartridge 1304 and/or
cut tissue captured between the anvil 1310 and the staple cartridge
1304 when the end effector 1300 is in the closed configuration.
Furthermore, the firing drive can be retracted by the motor 1102
from the advanced position, for example, the position illustrated
in FIG. 167A to a default or retracted position as illustrated in
FIG. 167B when the locking member 3082 is moved from the closed
configuration to the open configuration.
[0406] Further to the above, as described elsewhere in greater
detail, the proximal articulation drive 10030 of the surgical
instrument 1010 can be selectively coupled with the firing drive
1110 such that, when the firing drive 1110 is motivated by the
motor 5, the proximal articulation drive 10030 can be driven by the
firing drive 1110 and the proximal articulation drive 10030 can, in
turn, articulate the end effector 1300 relative to the shaft 1210
between the articulation home state position and the articulate
position, as described above. Furthermore, the firing drive 1110
can be decoupled from the proximal articulation drive 10030, for
example, when the end effector 1300 is in the closed configuration.
This arrangement permits the motor 1102 to motivate the firing
drive 1110 to move the firing member 10060 between the unfired
position and the fired position independent of the proximal
articulation drive 10030. Since the firing drive 1110 can be
decoupled from and moved independently from the proximal
articulation drive 10030, the controller 3002 may be configured to
guide the firing drive 1110 to locate and reconnect with the
proximal articulation drive 10030. In a way, the controller 3002
can remember where it left the proximal articulation drive 10030.
More particularly, the controller 3002 can, one, evaluate the
position of the firing drive 1110 when the proximal articulation
drive 10030 is decoupled from the firing drive 1110 and, two,
remember where the proximal articulation drive 10030 is when the
controller 3002 is instructed to reconnect the firing drive 1110
with the proximal articulation drive 10030. In such circumstances,
the controller 3002 can move the firing drive 1110 into a position
in which the clutch assembly 10070, for example, can reconnect the
proximal articulation drive 10030 to the firing drive 1110. The
controller 3002 may track the direction of rotation, speed of
rotation and the time of rotation of the motor 1102 when the firing
drive 1110 is coupled to the proximal articulation drive 10030 to
determine and store the location of the proximal articulation drive
10030, for example, in the memory 3010. Other parameters and
algorithms can be utilized to determine the location of the
proximal articulation drive 10030. In certain embodiments, the
firing drive 1110 may include a sensor configured to detect when
the firing drive 1110 is coupled to the proximal articulation drive
10030 and communicate the same to the controller 3002 to confirm
the coupling engagement between the firing drive 1110 and the
proximal articulation drive 10030. In certain embodiments, when the
controller 3002 is not configured to store and access the proximal
articulation drive 10030, the controller may activate the motor
1102 to motivate the firing drive 1110 to travel along its full
range of motion until the firing drive 1110 comes into coupling
arrangement with the proximal articulation drive 10030.
[0407] Referring now to FIGS. 151 and 165, the safe release system
3080 may react to an operator's attempt to separate the handle 1042
from the shaft 1210 by resetting the surgical instrument 1010 to
the home state, for example, as soon as the operator moves the
locking member 3082 from the locked configuration to the unlocked
configuration. As described above, the switch 3084 can be operably
coupled to the locking member 3082 such that when the locking
member 3082 is moved from the locked configuration to the unlocked
configuration, the switch 3084 may be moved to open the circuit
3086 thereby transmitting the home state input signal to the
controller 3002. Alternatively, movement of the switch 3084 from
its locked configuration to its unlocked configuration may allow
the circuit 3086 to close thereby transmitting the home state input
signal to the controller 3002.
[0408] Referring again to FIG. 168, the controller 3002, upon
receiving the home state input signal, may check the position of
the firing drive 1110 through the sensor 3015 and may check the
memory 3010 for the last updated articulation position of the end
effector and, correspondingly, the last position of the proximal
articulation drive 10030. If the controller 3002 determines that
the end effector 1300 is in the articulation home state position
and the firing drive 1110 is positioned such that it is coupled to
the proximal articulation drive 10030, the controller 3002 may take
no action and the user may remove the shaft assembly from the
handle. Alternatively, the controller 3002 may provide feedback to
the operator that the surgical instrument 1010 is at home state
and/or it is safe to separate the handle 1042 from the shaft 1210.
For example, the controller 3002 can be configured to activate a
sound and/or a light signal and/or transmit a message through a
display (not shown) coupled to the controller 3002 to alert the
operator that the surgical instrument 1010 is at home state and/or
it is safe to separate the handle 1042 from the shaft 1210.
However, if the controller 3002 determines that the end effector
1300 is not in the articulation home state position and the firing
drive 1110 is positioned such that it is coupled to the proximal
articulation drive 10030, the controller 3002 may activate the
motor 1102 to motivate the firing drive 1110 to move the proximal
articulation drive 10030 which can, in turn, articulate the end
effector 1300 relative to the shaft 1210 back to the articulation
home state position. Alternatively, if the controller 3002
determines that the end effector 1300 is in the articulation home
state position but the firing drive 1110 is not positioned such
that it is coupled to the proximal articulation drive 10030, the
controller 3002 may activate the motor 1102 to move the firing
drive 1110 to a position wherein the firing drive 1110 is couplable
to the articulation drive 9. In doing so, the firing member 9 may
retract the firing member 10060 to the firing home state position.
As described above, the controller 3002 may optionally provide the
feedback to the operator that the surgical instrument 1010 is at
home state and that it is safe to separate the handle 1042 from the
shaft 1210.
[0409] In certain embodiments, referring to FIG. 169, the
controller 3002, upon receiving the home state input signal, may
check whether the end effector 1300 is in the open configuration
through the sensor 3016. Other means for determining that the end
effector 1300 is in the open configuration can be employed. If the
controller 3002 determines that the end effector 1300 is in the
open configuration, the controller 3002 may proceed to reset the
surgical instrument 1010 to home state, as described above.
However, if the controller 3002, upon receiving the home state
input signal, determines that the end effector 1300 is in the
closed configuration, the controller 3002 may prompt the operator
to confirm that the operator wishes to separate the handle 1042
from the shaft 1210. This step can be a precautionary step to
prevent resetting the surgical instrument 1010 if the operator
accidentally moved the locking member 3082 thereby erroneously
transmitting a home state input signal to the controller 3002 while
the end effector 1300 is in use and clamping tissue, for example.
In certain embodiments, the controller 3002 may prompt the operator
by displaying a message on the display coupled to the controller
3002, for example, requesting the operator to return the end
effector 1300 to the open configuration by depressing the release
member 1072. In addition to the mechanical locking member 3082, the
safe release system 3080 may also include an electronic lock (not
shown) which may be controlled by the controller 3002. The
electronic lock can be configured to prevent the operator from
separating the handle 1042 and the shaft 1210 until the operator
depresses the release member 1072. If the operator does not release
the end effector 1300 to the open configuration, the controller
3002 may take no action. In other embodiments, the controller 3002
may alert the operator by displaying an error message or activating
a sound and/or a light signal. On the other hand, if the operator
releases the end effector 1300 to the open configuration, the
controller 3002 may reset the surgical instrument 1010 as described
above. If an electronic lock is used, the controller 3002 may then
release the electronic lock to permit the operator to separate the
handle 1042 from the shaft 1210. In addition, the controller 3002
may then alert the operator that it is now safe to remove the
handle 1042 from the shaft 1210, as described above.
[0410] In certain embodiments, it may be desirable to include a
warning step prior to resetting the surgical instrument 1010 to
home state in response to the home state input signal to provide an
operator with a chance to remedy an accidental unlocking of the
locking member 3082. For example, the controller 3002 can be
configured to react to a first transmission of the home state input
signal by asking the operator to confirm that the operator wishes
to reset the surgical instrument 1010, for example, through the
display. In certain embodiments, the operator may transmit a second
home state input signal to the controller 3002 within a
predetermined time period from the first home state input signal by
locking and unlocking the locking member 3082 a second time. The
controller 3002 can be configured to react to the second
transmission of the home state input signal if transmitted within
the predetermined time period from the first transmission by
resetting the surgical instrument 1010 to the home state, as
described above.
[0411] An electric motor for a surgical instrument described herein
can perform multiple functions. For example, a multi-function
electric motor can advance and retract a firing element during a
firing sequence. To perform multiple functions, the multi-function
electric motor can switch between different operating states. The
electric motor can perform a first function in a first operating
state, for example, and can subsequently switch to a second
operating state to perform a second function, for example. In
various circumstances, the electric motor can drive the firing
element distally during the first operating state, e.g., an
advancing state, and can retract the firing element proximally
during the second operating state, e.g., a retracting state. In
certain circumstances, the electric motor can rotate in a first
direction during the first operating state and can rotate in second
direction during the second operating state. For example, clockwise
rotation of the electric motor can advance the firing element
distally and counterclockwise rotation of the electric motor can
retract the firing element proximally. The electric motor can be
balanced or substantially balanced during the first and second
operating states such that background haptic feedback or "noise"
generated by the electric motor is minimized. Though the haptic
feedback can be minimized during the first and second operating
states, it may not be entirely eliminated in certain circumstances.
In fact, such "noise" may be expected by the operator during normal
operation of the surgical instrument and, as such, may not
constitute a feedback signal indicative of a particular condition
of the surgical instrument.
[0412] In various circumstances, the multi-function electric motor
can perform additional functions during additional operating
states. For example, during a third operating state, e.g., a
feedback state, the electric motor can generate amplified haptic or
tactile feedback in order to communicate a particular condition of
the surgical instrument to the operator thereof. In other words, a
multi-function electric motor can drive a firing element distally
and proximally during a firing sequence, e.g., the first operating
state and the second operating state, respectively, and can also
generate the amplified haptic feedback to communicate with the
operator of the surgical instrument, e.g., during the third
operating state. The amplified haptic feedback generated during the
third operating state can substantially exceed the background
haptic feedback or "noise" generated during the first and second
operating states. In various embodiments, the amplified haptic
feedback generated during the third operating state can constitute
a feedback signal to the operator that is indicative of a
particular condition of the surgical instrument. For example, the
electric motor can generate the amplified haptic feedback when a
predetermined threshold force is detected on the firing element. In
such embodiments, the amplified haptic feedback can constitute a
warning signal to the operator such as, for example, a potential
overload warning. In other embodiments, the amplified haptic
feedback can communicate a status update to the operator such as,
for example, a signal that the firing element has reached a
distal-most position and/or successfully completed a firing stroke.
In various embodiments, the electric motor can oscillate between
clockwise rotation and counterclockwise rotation during the third
operating state. As described herein, a resonator or amplifier
mounted to the electric motor can oscillate with the electric motor
to optimize or amplify the haptic feedback generated by the
electric motor. Though the resonator can amplify haptic feedback
during the third operating state, the resonator can be balanced
relative to its axis of rotation, for example, such that the
background haptic feedback or "noise" remains minimized during the
first and second operating states.
[0413] In various circumstances, the multi-function electric motor
can switch between different operating states. For example, the
electric motor can switch from the first operating state to the
second operating state in order to retract the firing element from
a distal position in an end effector. Furthermore, the electric
motor can switch to the third operating state to communicate a
signal indicative of a particular condition of the surgical
instrument to the operator. For example, when a
clinically-important condition is detected, the electric motor can
switch from the first operating state to the third operating state
in order to communicate the clinically-important condition to the
operator. In certain embodiments, the electric motor can generate
amplified haptic feedback to communicate the clinically-important
condition to the operator. When the electric motor switches to the
third operating state, the advancement of the firing element can be
paused. In various embodiments, upon receiving the amplified haptic
feedback, the operator can decide whether (A) to resume the first
operating state, or (B) to initiate the second operating state. For
example, where the clinically-important condition is a high force
on the firing element, which may be indicative of potential
instrument overload, the operator can decide (A) to resume
advancing the firing element distally, or (B) to heed the potential
overload warning and retract the firing element proximally. If the
operator decides to resume the first operating state despite the
potential for instrument overload, the instrument may be at risk of
failure. In various embodiments, a different electric motor can
generate feedback to communicate the clinically-important condition
to the operator. For example, a second electric motor can generate
sensory feedback such as a noise, a light, and/or a tactile signal,
for example, to communicate the clinically-important condition to
the operator.
[0414] Referring now to FIG. 170, an electric motor 5002 for a
surgical instrument (illustrated elsewhere) can comprise a motor
housing 5004 and a shaft 5006 extending from the motor housing
5004. While electric motor 5002 is described herein as one example,
other electric motors, such as motor 1102, for example, can
incorporate the teachings disclosed herein. The shaft 5006 can be
fixed to a rotor (not illustrated) positioned within the motor
housing 5004, and the shaft 5006 can rotate as the rotor rotates.
The shaft 5006 can rotate in one direction during a first operating
state, for example, and can rotate in a second direction during the
second operating state, for example. Furthermore, the rotation of
the electric motor 5002 in one direction can implement a first
surgical function, and the rotation of the electric motor 5002 in
another direction can implement a second surgical function. In
various embodiments, the electric motor 5002 and/or the shaft 5006
thereof can be operably coupled to a firing element (illustrated
elsewhere), and can drive the firing element during a firing
sequence. For example, clockwise rotation of the electric motor
5002 can drive the firing element distally, and counterclockwise
rotation of the electric motor 5002 can drive the firing element
proximally. Alternatively, counterclockwise rotation of the
electric motor 5002 can drive the firing element distally, and
clockwise rotation of the electric motor 5002 can drive the firing
element proximally. In other words, the electric motor can advance
the firing element during the first operating state and can retract
the firing element during the second operating state, or vice
versa. In other embodiments, the electric motor 5002 can be
operably coupled to an articulation mechanism (illustrated
elsewhere), and can articulate an end effector relative to a handle
of the surgical instrument. For example, clockwise rotation of the
electric motor 5002 can articulate the end effector in a first
direction, and counterclockwise rotation of the electric motor 5002
can articulate the end effector in a second direction.
[0415] In various embodiments, a resonator or amplifier 5020 can be
mounted on the shaft 5006 of the electric motor 5002. A washer 5008
can secure the resonator 5020 relative to the shaft 5006, for
example. Furthermore, the resonator 5020 can be fixedly secured to
the shaft 5006 such that the resonator 5020 rotates and/or moves
with the shaft 5006. In various embodiments, the resonator 5020
and/or various portions thereof can be fastened to the shaft 5006
and/or can be integrally formed therewith, for example.
[0416] Referring now to FIGS. 170-172, the resonator 5020 can
comprise a body 5022 comprising a mounting bore 5040 (FIGS. 171 and
172) for receiving the shaft 5006 (FIG. 170). For example, the
shaft 5006 can extend through the mounting bore 5040 when the
resonator 5020 is secured to the shaft 5006. The mounting bore 5040
and the shaft 5006 can be coaxial, for example. In various
embodiments, the body 5022 of the resonator 5020 can be balanced
and/or symmetrical relative to the mounting bore 5040, and the
center of mass of the body 5022 can be positioned along the central
axis of the mounting bore 5040, for example. In such embodiments,
the center of mass of the body 5022 can be positioned along the
axis of rotation of the shaft 5006, and the body 5022 can be
balanced relative to the shaft 5006, for example.
[0417] In various circumstances, the resonator 5020 can further
comprise a pendulum 5030 extending from the body 5022. For example,
the pendulum 5030 can comprise a spring or bar 5032 extending from
the body 5022 and a weight 5034 extending from the spring 5032. In
certain circumstances, the resonator 5020 and/or the pendulum 5030
thereof can be designed to have an optimized natural frequency. As
described herein, an optimized natural frequency can amplify the
haptic feedback generated when the electric motor 5002 oscillates
between clockwise and counterclockwise rotations, e.g., during the
third operating state. In various circumstances, the resonator 5020
can further comprise a counterweight 5024 extending from the body
5022. Referring primarily to FIG. 172, the pendulum 5030 can extend
from the body 5022 in a first direction X, and the counterweight
5024 can extend from the body 5022 in a second direction Y. The
second direction Y can be different than and/or opposite to the
first direction X, for example. In various embodiments, the
counterweight 5024 can be designed to balance the mass of the
pendulum 5030 relative to the mounting bore 5040 (FIGS. 171 and
172) through the body 5022. For example, the geometry and material
of the counterweight 5024 can be selected such that the center of
mass 5028 (FIG. 172) of the entire resonator 5020 is positioned
along the central axis of the mounting bore 5040 of the body 5022,
and thus, along the axis of rotation of the resonator 5020 and the
shaft 5006 (FIG. 170).
[0418] The center of mass 5028 of the resonator 5020 (CM.sub.R) can
be determined from the following relationship:
CM R = 1 m R ( CM B m B + CM C m C + CM S m s + CM W m W ) ,
##EQU00001##
where m.sub.R is the total mass of the resonator 5020, CM.sub.B is
the center of mass of the body 5022, CM.sub.C is the center of mass
of the counterweight 5024, CM.sub.S is the center of mass of the
spring 5032, CM.sub.W is the center of mass of the weight 5034,
m.sub.B is the mass of the body 5022, m.sub.C is the mass of the
counterweight 5024, m.sub.S is the mass of the spring 5032, and
m.sub.W is the mass of the weight 5034. Where the center of mass of
the body 5022 is positioned along the central axis of the mounting
bore 5040 and the resonator 5020 comprises a uniform thickness and
uniform density, the resonator 5020 can be balanced relative to the
central axis of the mounting bore 5040 according to the following
simplified relationship:
A.sub.CCM.sub.C=A.sub.SCM.sub.S+A.sub.WCM.sub.W,
wherein A.sub.C is the area of the counterweight 5024, A.sub.S is
the area of the spring 5032, and A.sub.W is the area of the weight
5034.
[0419] In various circumstances, when the center of mass 5028 of
the resonator 5020 is centered along the central axis of the
mounting hole 5040, and thus, along the axis of rotation of the
shaft 5006 (FIG. 170), the resonator 5020 can be balanced relative
to its axis of rotation thereof. In such embodiments, because the
resonator 5020 is balanced, the background haptic feedback can be
minimized during the first and second operating states. In various
circumstances, the resonator 5020 can include additional or fewer
components. The various components of the resonator 5020 can be
balanced such that the center of mass 5028 of the entire resonator
5020 is balanced relative to the axis of rotation of the resonator
5020. Additionally, in some embodiments, the material and/or
density of various components of the resonator 5020 can differ from
various other components of the resonator 5020. The material and/or
density of the various components can be selected to balance the
mass of the resonator 5020 relative to the axis of rotation and/or
to optimize the natural frequency of the resonator 5020 and/or the
pendulum 5030 thereof, as described herein.
[0420] Referring still to FIGS. 170-172, the spring 5032 of the
pendulum 5030 can be deflectable and/or deformable. For example,
rotation of the resonator 5020 can cause the spring 5032 of the
pendulum 5030 to deflect. The spring 5032 can deflect upon initial
rotation of the resonator 5020, and can remain deflected as the
resonator 5020 continues to rotate in the same direction and at the
same rotational speed. Because the deflection of the spring 5032
remains at least substantially constant during continued
substantially constant rotation of the resonator 5020 in one
direction, the background haptic feedback can remain minimized
during the first and second operating states. When the rotational
direction of the resonator 5020 changes, the spring 5032 can
deflect in a different direction. For example, the spring 5032 can
deflect in a first direction when the resonator 5020 rotates
clockwise and can deflect in a second direction when the resonator
5020 rotates counterclockwise. The second direction can be opposite
to the first direction, for example. In other words, as the
electric motor 5020 oscillates between clockwise rotation and
counterclockwise rotation, the spring 5032 can repeatedly deflect
in different directions in response to the changes in the direction
of rotation. Repeated deflections of the spring 5032 in opposite
directions, i.e., deflective oscillations, can generate the
amplified haptic feedback. For example, the haptic feedback
generated by the oscillating resonator 5020, which is driven by the
oscillating motor 5002 (FIG. 170), can be sufficiently amplified
such that it provides a signal to the operator indicative of a
particular condition of the surgical instrument. The amplified
haptic feedback generated by the oscillating resonator 5020 and
motor 5002 can be substantially greater than the background haptic
feedback generated during the sustained rotation of the resonator
5020 and motor 5002 in the same direction.
[0421] In use, the rotation of the pendulum 5030 can generate a
centrifugal force on the weight 5034, and the spring 5032 of the
pendulum 5030 can elongate in response to the centrifugal force. In
various embodiments, the resonator 5020 and/or the motor 5002 can
comprise a retainer for limiting radial elongation of the spring
5032. Such a retainer can retain the pendulum 5030 within a
predefined radial boundary 5050 (FIG. 170). In various
circumstances, the centrifugal force exerted on the weight 5034
during the third operating state may be insufficient to elongate
the pendulum 5030 beyond the redefined radial boundary 5050.
[0422] In various circumstances, the resonator 5020 can be designed
to amplify the haptic feedback generated by the electric motor 5002
(FIG. 170) during the third operating state. In other words, the
resonator 5020 can be designed such that the natural frequency of
the resonator 5020 is optimized, and the electric motor 5002 can
oscillate at a frequency that drives the resonator 5020 to
oscillate at its optimized natural frequency. In various
embodiments, the optimized natural frequency of the resonator 5020
can be related to the frequency of oscillations of the electric
motor 5002. The optimized natural frequency of the resonator 5020
can coincide with and/or correspond to the oscillation frequency of
the electric motor 5002, for example. In certain embodiments, the
optimized natural frequency of the resonator 5020 can be offset
from the oscillation frequency of the electric motor 5002, for
example.
[0423] In certain embodiments, the natural frequency of the
resonator 5020 can be approximated by the natural frequency of the
pendulum 5030. For example, substantially non-oscillating
components can be ignored in the natural frequency approximation.
In certain embodiments, the body 5022 and the counterweight 5024
can be assumed to be substantially non-oscillating components of
the resonator 5020, and thus, assumed to have a negligible or
inconsequential effect on the natural frequency of the resonator
5020. Accordingly, the oscillating component of the resonator 5020,
e.g., the pendulum 5030, can be designed to amplify the haptic
feedback generated by the electric motor 5002 (FIG. 170) during the
third operating state. Where the mass of the spring 5032 is
substantially less than the mass of the weight 5034, the natural
frequency of the pendulum 5030 (f.sub.P) can be approximated by the
following relationship:
f P .apprxeq. 1 2 .pi. k s m W , ##EQU00002##
wherein k.sub.S is the spring constant of the spring 5032 and
m.sub.W is the mass of the weight 5034. The spring constant of the
spring 5032 (k.sub.S) can be determined from the following
relationship:
k s = 3 E S I S L S 3 , ##EQU00003##
where E.sub.S is the modulus of elasticity of the spring 5032,
I.sub.S is the second moment of inertia of the spring 5032, and
L.sub.S is the length of the spring 5032. In various embodiments,
the spring constant (k.sub.S) of the spring 5032 and/or the mass of
the weight 5034 (m.sub.W) can be selected such that the natural
frequency of the pendulum 5030 (f.sub.P) relates to the oscillation
frequency of the electric motor 5002 during the third operating
state. For example, the natural frequency of the pendulum 5030 can
be optimized by varying the spring constant of the spring 5032
and/or the mass of the weight 5034.
[0424] Referring still to FIGS. 170-172, the natural frequency of
the resonator 5020 and/or the pendulum 5030 thereof can be
optimized to a frequency that provides the optimal haptic feedback
to the operator. For example, the natural frequency of the
resonator 5020 can be optimized to between approximately 50 Hz and
approximately 300 Hz in order to enhance the feedback experienced
by the operator. In some embodiments, the natural frequency of the
resonator 5020 can be optimized to a frequency less than
approximately 50 Hz, for example, and, in other embodiments, the
resonator 5020 can be optimized for a frequency greater than
approximately 300 Hz, for example. Furthermore, the electric motor
5002 (FIG. 170) can oscillate at a frequency that drives the
resonator 5020 to oscillate at or near the natural frequency
thereof. In certain embodiments, the electric motor 5002 can drive
the resonator 5020 to oscillate within a range of amplifying
frequencies inclusive of the natural frequency of the resonator
5020.
[0425] In various embodiments, the oscillation frequency of the
electric motor 5002 can coincide with and/or correspond to the
natural frequency of the resonator 5020 in order to drive the
resonator 5020 at or near its natural frequency. In certain
embodiments, the oscillation frequency of the electric motor 5002
can be near or at the natural frequency of the resonator 5020 and,
in other embodiments, the oscillation frequency of the electric
motor 5002 can be offset from the natural frequency of the
resonator 5020. In various embodiments, the oscillation frequency
of the electric motor 5002 can be optimized to coincide with the
natural frequency of the resonator 5020. Furthermore, in certain
embodiments, the oscillation frequency of the electric motor 5002
and the natural frequency of the resonator 5020 can be
cooperatively selected, designed and/or optimized to amplify the
haptic feedback generated by the electric motor 5002 during the
third operating state.
[0426] Referring primarily to FIG. 170, the electric motor 5002 can
generate the amplified haptic feedback when the electric motor 5002
oscillates between the clockwise direction and the counterclockwise
direction during the third operating state. Additionally, the
rotation of the electric motor 5002 during the first and second
operating states can drive the firing member (illustrated
elsewhere) during a firing stroke. For example, clockwise rotation
of the electric motor 5002 can advance the firing element distally
and counterclockwise rotation of the electric motor 5002 can
retract the firing element proximally. Accordingly, when the
electric motor 5002 oscillates between the clockwise direction and
the counterclockwise direction, the distal end of the firing
element may move between a slightly more distal position and a
slightly more proximal position. However, the electric motor 5002
can be significantly geared down such that oscillations of the
electric motor 5002 during the third operating state move the
distal end of the firing element an insignificant and/or
imperceptible distance. In various embodiments, the gear ratio can
be approximately 200:1 to approximately 800:1, for example. In
certain embodiments, the firing element can remain stationary
during the third operating state. For example, slack between the
motor 5002 and distal end of the firing element can absorb the
oscillations of the electric motor 5002. For instance, referring to
FIGS. 102-104, such slack is present between the firing member
10060 and the knife bar 10066. In various circumstances, the knife
bar 10066 can comprise a drive tab 10065 which extends into a drive
slot 10064 defined in the firing member 10060 wherein the length of
the drive slot 10064 between a distal end 10067 and a proximal end
10069 thereof can be longer than the drive tab 10065. In use,
sufficient travel of the firing member 10060 must occur before the
distal end 10067 or the proximal end 10069 come into contact with
the drive tab 10065.
[0427] Referring now to FIGS. 173-176, the electric motor 5002
(FIGS. 173 and 174) can be positioned within a handle 5101 (FIG.
173) of a surgical instrument 5100 (FIG. 173). In various
embodiments, a resonator or amplifier 5120 can be mounted on the
shaft 5006 of the electric motor 5002. The shaft 5006 can be fixed
to the rotor (not illustrated) positioned within the motor housing
5004, and the shaft 5006 can rotate as the rotor rotates. The
washer 5008 can secure the resonator 5120 relative to the shaft
5006, for example. Furthermore, the resonator 5120 can be secured
to the shaft 5006 such that the resonator 5120 rotates and/or moves
with the shaft 5006. In some circumstances, a key can be utilized
to transmit the rotational movement of the shaft 5006 to the
resonator 5120, for example. In various circumstances, the
resonator 5120 and/or various portions thereof can be fastened to
the shaft 5006 and/or can be integrally formed therewith, for
example.
[0428] Referring primarily to FIGS. 175 and 176, similar to the
resonator 5020, the resonator 5120 can comprise a body 5122
comprising a mounting bore 5140 for receiving the shaft 5006 (FIGS.
173 and 174) of the electric motor 5002 (FIGS. 173 and 174). For
example, the shaft 5006 can extend through the mounting bore 5140
when the resonator 5120 is secured to the shaft 5006. In various
embodiments, the body 5122 of the resonator 5120 can be balanced
and symmetrical relative to the mounting bore 5140, and the center
of mass of the body 5122 can be positioned along the central axis
of the mounting bore 5140, for example. Further, the center of mass
of the body 5122 can be positioned along the axis of rotation of
the resonator 5120 and the shaft 5006 such that the body 5122 is
balanced relative to the shaft 5006, for example.
[0429] In various embodiments, the resonator 5120 can further
comprise a pendulum 5130 extending from the body 5122. For example,
the pendulum 5130 can comprise a spring or bar 5132 extending from
the body 5122 and a weight 5134 extending from the spring 5132. In
certain embodiments, the spring 5132 can extend along an axis that
defines at least one contour between the body 5122 and the weight
5134. The spring 5132 can wind, bend, twist, turn, crisscross,
and/or zigzag, for example. The geometry of the spring 5132 can
affect the spring constant thereof, for example. In at least one
embodiment, the spring 5132 can form a first loop 5137 on a first
lateral side of the resonator 5120 and a second loop 5138 on a
second lateral side of the resonator 5120. An intermediate portion
5139 of the spring 5132 can traverse between the first and second
loops 5137, 5138, for example. Similar to the spring 5032, the
spring 5132 can be deflectable, and can deflect in response to
rotations and/or oscillations of the resonator 5120. Furthermore,
in certain embodiments, the weight 5134 can include a pin 5136,
which can provide additional mass to the weight 5134, for example.
As described herein, the mass of the weight 5134 and the geometry
and properties of the spring 5132 can be selected to optimize the
natural frequency of the pendulum 5130, and thus, the natural
frequency of the entire resonator 5120, for example.
[0430] Referring still to FIGS. 175 and 176, the resonator 5120 can
further comprise a counterweight 5124 extending from the body 5122.
In certain embodiments, a pin 5126 can extend from the
counterweight 5124, and can provide additional mass to the
counterweight 5124, for example. The pendulum 5130 can extend from
the body 5122 in a first direction X, and the counterweight 5124
can extend from the body 5122 in a second direction Y. The second
direction Y can be different than and/or opposite to the first
direction X, for example. In various embodiments, the counterweight
5124 can be designed to balance the mass of the pendulum 5130
relative to the mounting bore 5140 through the body 5120. For
example, the geometry and material of the counterweight 5124 can be
selected such that the center of mass 5128 of the resonator 5120 is
positioned along the central axis of the mounting bore 5140 of the
body 5122, and thus, along the axis of rotation A (FIG. 173) of the
resonator 5120.
[0431] Similar to the resonator 5020, the resonator 5120 can be
designed to amplify the haptic feedback generated by the electric
motor 5002 (FIGS. 173 and 174) during the third operating state. In
other words, the resonator 5120 can be designed such that the
natural frequency of the resonator 5120 is optimized, and the
electric motor 5002 can oscillate at a frequency that drives the
resonator 5120 to oscillate at or near its optimized natural
frequency. For example, the electric motor 5002 can drive the
resonator 5120 to oscillate within a range of amplifying
frequencies inclusive of the natural frequency of the resonator
5120. In certain embodiments, the natural frequency of the
resonator 5120 can be approximated by the natural frequency of the
pendulum 5130. In such embodiments, the pendulum 5130 can be
designed to amplify the haptic feedback generated by the electric
motor 5002 during the third operating state. For example, the
pendulum 5130 can be designed to have an optimized natural
frequency, and the electric motor 5002 can drive the resonator 5120
to oscillate at or near the optimized natural frequency of the
pendulum 5130 in order to amplify the haptic feedback generated
during the third operating state.
[0432] Referring now to FIGS. 177-180, the electric motor 5002
(FIGS. 177 and 178) can be positioned within the handle 5101 (FIG.
177) of the surgical instrument 5100 (FIG. 177). In various
embodiments, a resonator or amplifier 5220 can be mounted on the
shaft 5006 (FIG. 170) of the electric motor 5002. The shaft 5006
can be fixed to the rotor (not illustrated) positioned within the
housing 5004, and the shaft 5006 can rotate as the rotor rotates.
The washer 5008 (FIG. 170) can secure the resonator 5220 relative
to the shaft 5006, for example. Furthermore, the resonator 5220 can
be secured to the shaft 5006 such that the resonator 5220 rotates
and/or moves with the shaft 5006. In various embodiments, the
resonator 5220 and/or various portions thereof can be fastened to
the shaft 5006 and/or can be integrally formed therewith, for
example.
[0433] Referring primarily to FIGS. 179 and 180, similar to the
resonators 5020, 5120, the resonator 5220 can comprise a body 5222
comprising a mounting bore 5240 for receiving the shaft 5006 (FIGS.
176 and 177) of the electric motor 5002 (FIGS. 176 and 177). For
example, the shaft 5006 can extend through the mounting bore 5240
when the resonator 5220 is secured to the shaft 5006. In various
embodiments, the body 5222 of the resonator 5220 can be balanced
and symmetrical relative to the mounting bore 5240, and the center
of mass of the body 5222 can be positioned along the central axis
of the mounting bore 5240, for example. Further, the center of mass
of the body 5222 can be positioned along the axis of rotation of
the shaft 5006 such that the body 5222 is balanced relative to the
shaft 5006, for example.
[0434] In various embodiments, the resonator 5220 can further
comprise a pendulum 5230 extending from the body 5222. For example,
the pendulum 5230 can comprise a spring or bar 5232 extending from
the body 5222 and a weight 5234 extending from the spring 5232. In
various embodiments, the spring 5232 can curve, wind, bend, twist,
turn, crisscross, and/or zigzag between the body 5222 and the
weight 5234. Furthermore, in certain embodiments, the weight 5234
can include a pin 5236, which can provide additional mass to the
weight 5234, for example. As described herein, the mass of the
weight 5234 and the geometry and properties of the spring 5232 can
be selected to optimize the natural frequency of the pendulum 5230,
and thus, the natural frequency of the entire resonator 5220, for
example.
[0435] In various embodiments, a retainer can limit or constrain
radial elongation of the spring 5232 and/or the pendulum 5230
during rotation and/or oscillation. For example, a retainer can
comprise a barrier or retaining wall around at least a portion of
the pendulum 5230. During the first and second operating states,
for example, the spring 5232 may deform and extend the weight 5234
toward the barrier, which can prevent further elongation of the
spring 5232. For example, referring primarily to FIGS. 179 and 180,
the resonator 5220 can comprise a retainer 5244. The retainer 5244
can comprise a first leg 5246, which can be secured to the body
5222 and/or to a counterweight 5224 of the resonator 5220. The
first leg 5246 can be fixed to the resonator 5220, and can be
formed as an integral piece therewith and/or fastened thereto, for
example. The retainer 5244 can further comprise a second leg or
barrier leg 5248, which can extend past the weight 5234 of the
pendulum 5230 when the spring 5232 is undeformed. The barrier leg
5248 can define the radial boundary 5050 beyond which the pendulum
5230 cannot extend. In other words, the barrier leg 5248 can block
radial extension of the pendulum 5230. For example, the barrier leg
5248 can be out of contact with the pendulum 5230 when the spring
5232 is undeformed because the pendulum 5230 can be positioned
within the radial boundary 5050. In other words, a gap 5249 (FIG.
180) can be defined between the weight 5234 and the barrier leg
5248 when the spring 5234 is undeformed. Further, the barrier leg
5248 can remain out of contact with the pendulum 5230 when the
resonator 5220 oscillates during the third operating state. For
example, the centrifugal force on the oscillating pendulum 5230
during the third operating state may be insufficient to extend the
weight 5234 of the pendulum 5230 beyond the predefined radial
boundary 5050 of the motor 5002. Though the gap 5249 may be reduced
during the third operating state, the weight 5234 can remain out of
contact with the barrier leg 5248, for example. In such
embodiments, the natural frequency of the pendulum 5230 can be
substantially unaffected by the retainer 5244 during the third
operating state.
[0436] In various embodiments, when the resonator 5220 rotates
during the first and second operating states, the spring 5232 of
the pendulum 5230 can be substantially deformed and/or elongated.
For example, the rotation of the resonator 5220 can generate a
centrifugal force on the spring 5232, and the spring 5232 may
elongate in response to the centrifugal force. In certain
embodiments, the weight 5234 of the pendulum 5230 can move toward
and into abutting contact with the barrier leg 5248 of the retainer
5244. In such embodiments, the barrier 5248 can limit or constrain
further radial elongation of the spring 5232 during the first and
second operating states.
[0437] In various embodiments, the retainer 5244 can be
substantially rigid such that the retainer 5244 resists deformation
and/or elongation. In certain embodiments, the retainer 5244 can be
integrally formed with the resonator 5220 and/or secured relative
thereto. In some embodiments, the retainer 5244 can be secured to
the motor 5002 (FIGS. 177 and 1781). For example, the retainer 5244
can be fixed relative to the rotor and/or the shaft 5006 (FIGS. 177
and 178) of the motor 5002 and can rotate and/or move therewith. In
such embodiments, the retainer 5244 can rotate with the resonator
5220, for example. In various embodiments, the retainer 5244 can be
fastened to the motor 5002 and/or can be integrally formed
therewith, for example. In certain embodiments, the retainer 5244
can remain stationary relative to the rotating shaft 5008 and/or
resonator 5220, for example.
[0438] Referring still to FIGS. 179 and 180, the resonator 5220 can
further comprise the counterweight 5224 extending from the body
5222. In certain embodiments, a pin 5226 can extend from the
counterweight 5224, and can provide additional mass to the
counterweight 5224, for example. The pendulum 5230 can extend from
the body 5222 in a first direction, and the counterweight 5224 can
extend from the body 5222 in a second direction. The second
direction can be different than and/or opposite to the first
direction of the pendulum 5230, for example. In various
embodiments, the counterweight 5224 can be designed to balance the
mass of the pendulum 5230 and the retainer 5244 relative to the
mounting bore 5240 through the body 5220 of the resonator 5220. For
example, the geometry and material of the counterweight 5224 can be
selected such that the center of mass 5228 of the resonator 5220 is
positioned along the central axis of the mounting bore 5240 of the
body 5222, and thus, along the axis of rotation A (FIG. 177) of the
shaft 5008 (FIGS. 177 and 178) and the resonator 5220.
[0439] Similar to the resonators 5020, 5120, the resonator 5220 can
be designed to amplify the haptic feedback generated by the
electric motor 5002 during the third operating state. In other
words, the resonator 5220 can be designed such that the natural
frequency of the resonator 5220 is optimized, and the electric
motor 5002 can oscillate at a frequency that drives the resonator
5220 to oscillate at or near its optimized natural frequency. For
example, the electric motor 5002 can drive the resonator 5220 to
oscillate within a range of amplifying frequencies inclusive of the
natural frequency of the resonator 5220. In certain embodiments,
the natural frequency of the resonator 5220 can be approximated by
the natural frequency of the pendulum 5230. In such embodiments,
the pendulum 5230 can be designed to amplify the haptic feedback
generated by the electric motor 5002 during the third operating
state. For example, the pendulum 5230 can be designed to have an
optimized natural frequency, and the electric motor 5002 can drive
the resonator 5220 to oscillate at or near the optimized natural
frequency of the pendulum 5230 to amplify the haptic feedback
generated during the third operating state.
[0440] Referring now to FIG. 181, the electric motor 5002 can be
positioned within the handle 5101 of the surgical instrument 5100.
In various embodiments, a resonator or amplifier 5320, similar to
resonator 5220, for example, can be mounted on the shaft 5006 (FIG.
170) of the electric motor 5002. The resonator 5320 can comprise a
body 5322 comprising a mounting bore 5340, for example, a pendulum
5330 comprising a spring 5332, a weight 5334, and a pin 5336, for
example, and a counterweight 5324 comprising a pin 5326, for
example. In various embodiments, the center of mass of the
resonator 5320 can lie along the axis of rotation A, and the
geometry and material of the resonator 5230 can be selected to
optimize the natural frequency thereof.
[0441] In various embodiments, a retaining ring 5344, similar to
retainer 5244, can limit or constrain radial elongation of the
spring 5332 and/or the pendulum 5230 during rotation and/or
oscillation. In various embodiments, the retaining ring 5344 can
comprise a barrier or retaining wall around at least a portion of
the pendulum 5330. In certain embodiments, the retaining ring 5344
can comprise a ring encircling the resonator 5320, for example. In
various embodiments, the retaining ring 5344 can be attached to the
electric motor 5002, such as the motor housing 5004, for example.
In other embodiments, the retaining ring 5344 can be attached to
the handle 5101 of the surgical instrument 5100, for example. In
still other embodiments, the retaining ring 5344 can be attached to
the rotor and/or the shaft 5006 (FIG. 170) of the electric motor
5002 such that the retaining ring 5344 rotates with the shaft 5006
and/or the resonator 5320, for example. In various embodiments, the
retaining ring 5344 can be substantially rigid such that it resists
deformation and/or elongation.
[0442] The retaining ring 5344 can define the radial boundary
beyond which the pendulum 5330 cannot extend. For example, the
pendulum 5330 can be out of contact with the retaining ring 5344
when the spring 5332 is undeformed. In other words, a gap can be
defined between the weight 5334 of the pendulum 5330 and the
retaining ring 5344 when the spring 5334 is undeformed. Further,
the pendulum 5330 can remain out of contact with the retaining ring
5344 when the resonator 5320 oscillates during the third operating
state. For example, the centrifugal force on the oscillating
pendulum 5330 during the third operating state may be insufficient
to extend the weight 5334 of the pendulum 5330 beyond the
predefined radial boundary. Though the gap defined between the
weight 5334 and the retaining ring 5344 may be reduced during the
third operating state, the weight 5334 can remain out of contact
with the retaining ring 5344, for example. In such embodiments, the
natural frequency of the pendulum 5330 can be substantially
unaffected by the retaining ring 5344 during the third operating
state.
[0443] In various embodiments, when the resonator 5320 rotates
during the first and second operating states, the spring 5332 of
the pendulum 5330 can be substantially deformed and/or elongated.
For example, the rotation of the resonator 5320 can generate a
centrifugal force on the spring 5332, and the spring 5332 may
elongate in response to the centrifugal force. In certain
embodiments, the weight 5334 of the pendulum 5330 can move toward
and into abutting contact with the retaining ring 5344. In such
embodiments, the retaining ring 5344 can limit or constrain further
radial elongation of the spring 5332 during the first and second
operating states.
[0444] In various embodiments, the surgical instrument 5100 (FIG.
177) can comprise a control system (not shown), which can control
the electric motor 5002. In various embodiments, the control system
can comprise one or more computers, processors, microprocessors,
circuits, circuit elements (e.g., transistors, resistors,
capacitors, inductors, and so forth), integrated circuits,
application specific integrated circuits (ASIC), programmable logic
devices (PLD), digital signal processors (DSP), field programmable
gate array (FPGA), logic gates, registers, semiconductor device,
chips, microchips, and/or chip sets, for example. The control
system can initiate, pause, resume, and/or terminate various
operating states of the electric motor 5002. For example, the
electric motor 5002 can perform a first function, e.g., advancing
the firing element distally, during the first operating state, and
can subsequently switch to the second operating state to perform a
second function, e.g., retracting the firing element proximally.
The firing element can be advanced distally to transect a
predefined length of tissue, and/or to eject and/or form a
predefined number of staples (illustrated elsewhere), for example.
In various embodiments, when the predefined length of tissue has
been transected and/or the predefined number of staples have been
ejected and/or formed, the control system can control the electric
motor 5002 to switch to the second operating state. The firing
element can be retracted proximally during the second operating
state to prepare for a subsequent firing stroke, for example. In
certain embodiments, the electric motor 5002 can switch to the
third operating state before the firing element completes the
predefined transection length, and/or ejection and/or formation of
the predefined number of staples. For example, the electric motor
5002 can prematurely switch from the first operating state to the
third operating state to communicate a signal indicative of a
condition of the surgical instrument to the operator. In various
embodiments, the electric motor 5002 can switch to the third
operating sate to communicate a potential overload warning signal
to the operator. In other embodiments, the amplified haptic
feedback can communicate a status update to the operator such as,
for example, a signal that the firing element has reached a
distal-most position and/or successfully completed a firing
stroke.
[0445] In various embodiments, the surgical instrument 5100 may be
designed to overcome a maximum threshold force in order to transect
tissue. When the force applied to the firing element exceeds the
maximum threshold force, the surgical instrument 5100 may not
perform as intended. For example, when the firing element attempts
to transect thicker and/or tougher tissue, the thicker and/or
tougher tissue may exert a force on the firing element that exceeds
the maximum threshold force. Accordingly, the firing element may be
unable to transect the thicker and/or tougher tissue. In such
embodiments, the electric motor 5002 can switch to the third
operating state in order to warn the operator that overload and/or
failure of the surgical instrument 5100 is possible. In various
embodiments, the surgical instrument 5100 can comprise a sensor
(not shown). The sensor can be positioned in the end effector
(illustrated elsewhere), for example, and can be configured to
detect the force applied to the firing element during the firing
sequence. In certain embodiments, the sensor and the control system
can be in signal communication. In such embodiments, when the force
detected by the sensor exceeds the maximum threshold force, the
control system can switch the electric motor 5002 to the third
operating state. In the third operating state, as described herein,
advancement of the firing element can be paused and the electric
motor can generate amplified haptic feedback to communicate the
potential overload warning to the operator.
[0446] In response to the amplified haptic feedback, the operator
can decide whether to resume the first operating state or to
initiate the second operating state. For example, the operator can
decide to resume advancement of the firing element distally, i.e.,
operate the surgical instrument in a warned operating state, or to
heed the potential overload warning and retract the firing element
proximally, i.e., operate the surgical instrument in a modified
operating state. If the operator decides to operate the surgical
instrument in the warned operating state, the surgical instrument
5100 may be at risk of failure. In various embodiments, the
surgical instrument 5100 can comprise an input key (not shown),
such as a plurality of lever(s) and/or button(s), for example. In
various embodiments, the input key can be in signal communication
with the control system. The operator can control the surgical
instrument by entering input via the input key. For example, the
operator can select a first button of the input key to resume
advancement of the firing element, i.e., enter the warned operating
state, or can select a second button of the input key to retract
the firing element, i.e., enter the modified operating state. In
various embodiments, the operator can select an additional button
and/or lever to select yet a different operating state.
[0447] Though the surgical instrument 5100 may fail when operated
in the warned operating state, the operator of the surgical
instrument 5100 may decide that the failure risk is outweighed by
the necessity and/or urgency of the surgical function. For example,
when time is essential, the operator may decide that the risk of
instrument failure is outweighed by a critical need to
expeditiously complete (or attempt to complete) a surgical
transection and/or stapling. Furthermore, by allowing the operator
to determine the course of action, the holistic knowledge of the
operator can be applied to the surgical procedure, and the operator
is less likely to become confused and/or frustrated with the
surgical instrument 5100.
[0448] In various embodiments, a different motor can generate
feedback to communicate with the operator. For example, a first
motor can drive the firing member during a firing sequence, and a
second motor can generate feedback. In various embodiments, the
second motor can generate sensory feedback such as, for example, a
noise, a light, and/or a tactile signal to communicate with the
operator. Furthermore, in certain embodiments, the control system
can control the multiple motors of the surgical instrument.
[0449] Referring primarily to FIG. 180, a method of operating a
surgical system or surgical instrument can include a plurality of
operating states of the surgical instrument. For example, the
surgical instrument can first operate in an initial operating state
5402, and can subsequently operate in one of the secondary
operating states 5412 or 5414. The secondary operating state can be
a warned operating state 5412, for example, or a modified operating
state 5414, for example. When the surgical instrument operates in
the initial operating state 5402, an initial surgical function can
be initiated at step 5404. The initial surgical function can be one
or more of various functions of the surgical instrument, such as,
clamping tissue between jaws of an end effector, articulating the
end effector, advancing the firing member, retracting the firing
member, opening the end effector jaws, and/or repeating and/or
combining various function(s), for example. After initiation of the
initial surgical function, the surgical instrument can detect a
condition of the surgical instrument at step 5406. For example,
where the initial surgical function is advancing the firing member,
a sensor can detect a clinically-important condition, such as a
force on the advancing firing member that exceeds a threshold
force, for example.
[0450] Referring still to FIG. 180, in response to the detected
condition, the surgical instrument can pause the initial surgical
function at step 5408. Further, at step 5410 the surgical
instrument can provide feedback to the operator of the surgical
instrument. The feedback can be a sensory feedback, such as a
noise, a light, and/or a tactile signal, for example. In certain
embodiments, a first motor can pause the initial surgical function
and a second motor can generate the sensory feedback.
Alternatively, as described herein, a multi-function electric
motor, such as the electric motor 5002, for example, can switch
from the first operating state, or advancing state, to the third
operating state, or feedback state, in which the electric motor
oscillates to generate the amplified haptic feedback. When the
multi-function electric motor oscillates to generate the amplified
haptic feedback, advancement and/or retraction of the firing
element can be paused and/or reduced to an insignificant and/or
imperceptible amount due to the high gear ratio between the
electric motor and the firing member. In such embodiments, where
the multi-function motor switches from the first operating state to
the third operating state, pausing of the initial surgical function
at step 5408 and providing feedback to the operator at step 5410
can occur simultaneously or nearly simultaneously, for example.
[0451] In certain embodiments, after the surgical instrument has
communicated feedback indicative of a particular condition to the
operator, the operator can determine how to proceed. For example,
the operator can decide between a plurality of possible operating
states. In various embodiments, the operator can decide to enter a
warned operating state 5412, or a modified operating state 5414.
For example, referring still to FIG. 180, the operator can select
the initial surgical function at step 5416, or can select a
modified surgical function at step 5418. In various embodiments,
the operator can interface with a key, button, and/or lever, for
example, to select one of the secondary operating states. If the
operator selects the initial surgical function at step 5416, the
surgical instrument can resume the initial surgical function at
step 5418. If the operator selects the modified surgical function
at step 5420, the surgical instrument can initiate the modified
surgical function at step 5422.
[0452] FIGS. 183-192 illustrate various embodiments of an
apparatus, system, and method for absolute position sensing on
rotary or linear drive endocutter. Microcontroller controlled
endocutters require position and velocity values to be able to
properly control articulation, firing, and other surgical
functions. This has been accomplished in the past via use of rotary
encoders attached to the drive motors, which enable the
microcontroller to infer the position by counting the number of
steps backwards and forwards the motor has taken. It is preferable,
in various circumstances, to replace this system with a compact
arrangement which provides a unique position signal to the
microcontroller for each possible location of the drive bar or
knife. Various exemplary implementations of such absolute position
sensor arrangements for rotary or linear drive endocutter are now
described with particularity in connection with FIGS. 183-192.
[0453] FIG. 183 is an exploded perspective view of a surgical
instrument handle 1042 of FIG. 34 showing a portion of a sensor
arrangement 7002 for an absolute positioning system 7000, according
to one embodiment. The surgical instrument handle 1042 of FIG. 34
has been described in detail in connection with FIG. 34.
Accordingly, for conciseness and clarity of disclosure, other than
describing the elements associated with the sensor arrangement 7002
for an absolute positioning system 7000, such detailed description
of the surgical instrument handle 1042 of FIG. 34 will not be
repeated here. Accordingly, as shown in FIG. 183, the surgical
instrument handle 1042 of the housing 1040 operably supports a
firing drive system 1100 that is configured to apply firing motions
to corresponding portions of the interchangeable shaft assembly.
The firing drive system 1100 may employ an electric motor 1102. In
various forms, the motor 1102 may be a DC brushed driving motor
having a maximum rotation of, approximately, 25,000 RPM, for
example. In other arrangements, the motor may include a brushless
motor, a cordless motor, a synchronous motor, a stepper motor, or
any other suitable electric motor. A battery 1104 (or "power
source" or "power pack"), such as a Li ion battery, for example,
may be coupled to the handle 1042 to supply power to a control
circuit board assembly 1106 and ultimately to the motor 1102. The
battery pack housing 1104 may be configured to be releasably
mounted to the handle 1042 for supplying control power to the
surgical instrument 1010 (FIG. 33). A number of battery cells
connected in series may be used as the power source to power the
motor. In addition, the power source may be replaceable and/or
rechargeable.
[0454] As outlined above with respect to other various forms, the
electric motor 1102 can include a rotatable shaft (not shown) that
operably interfaces with a gear reducer assembly 1108 that is
mounted in meshing engagement with a with a set, or rack, of drive
teeth 1112 on a longitudinally-movable drive member 1110. In use, a
voltage polarity provided by the battery can operate the electric
motor 1102 in a clockwise direction wherein the voltage polarity
applied to the electric motor by the battery can be reversed in
order to operate the electric motor 1102 in a counter-clockwise
direction. When the electric motor 1102 is rotated in one
direction, the drive member 1110 will be axially driven in the
distal direction "D". When the motor 1102 is driven in the opposite
rotary direction, the drive member 1110 will be axially driven in a
proximal direction "P". The handle 1042 can include a switch which
can be configured to reverse the polarity applied to the electric
motor 1102 by the battery. As with the other forms described
herein, the handle 1042 can also include a sensor that is
configured to detect the position of the drive member 1110 and/or
the direction in which the drive member 1110 is being moved.
[0455] FIG. 184 is a side elevational view of the handle of FIG.
183 with a portion of the handle housing removed showing a portion
of a sensor arrangement 7002 for an absolute positioning system
7000, according to one embodiment. The housing 1040 of the handle
1042 supports the control circuit board assembly 1106, which
comprises the necessary logic and other circuit components
necessary to implement the absolute positioning system 7000.
[0456] FIG. 185 is a schematic diagram of an absolute positioning
system 7000 comprising a microcontroller 7004 controlled motor
drive circuit arrangement comprising a sensor arrangement 7002,
according to one embodiment. The electrical and electronic circuit
elements associated with the absolute positioning system 7000
and/or the sensor arrangement 7002 are supported by the control
circuit board assembly 1106. The microcontroller 7004 generally
comprises a memory 7006 and a microprocessor 7008 ("processor")
operationally coupled. The processor 7008 controls a motor driver
7010 circuit to control the position and velocity of the motor
1102. The motor 1102 is operatively coupled to a sensor arrangement
7002 and an absolute position sensor 7012 arrangement to provide a
unique position signal to the microcontroller 7004 for each
possible location of a drive bar or knife of the surgical
instrument 1010 (FIG. 33). The unique position signal is provided
to the microcontroller 7004 over feedback element 7024. It will be
appreciated that the unique position signal may be an analog signal
or digital value based on the interface between the position sensor
7012 and the microcontroller 7004. In one embodiment described
hereinbelow, the interface between the position sensor 7012 and the
microcontroller 7004 is standard serial peripheral interface (SPI)
and the unique position signal is a digital value representing the
position of a sensor element 7026 over one revolution. The value
representative of the absolute position of the sensor element 7026
over one revolution can be stored in the memory 7006. The absolute
position feedback value of the sensor element 7026 corresponds to
the position of the articulation and knife elements. Therefore, the
absolute position feedback value of the sensor element 7026
provides position feedback control of the articulation and knife
elements.
[0457] The battery 1104, or other energy source, provides power for
the absolute positioning system 7000. In addition, other sensor(s)
7018 may be provided to measure other parameters associated with
the absolute positioning system 7000. One or more display
indicators 7020, which may include an audible component, also may
provided.
[0458] As shown in FIG. 185, a sensor arrangement 7002 provides a
unique position signal corresponding to the location of the
longitudinally-movable drive member 1110. The electric motor 1102
can include a rotatable shaft 7016 that operably interfaces with a
gear assembly 7014 that is mounted in meshing engagement with a
with a set, or rack, of drive teeth 1112 (FIG. 183) on the
longitudinally-movable drive member 1110. The sensor element 7026
may be operably coupled to the gear assembly 7104 such that a
single revolution of the sensor element 7026 corresponds to some
linear longitudinal translation of the longitudinally-movable drive
member 1110, as described in more detail hereinbelow. In one
embodiment, an arrangement of gearing and sensors can be connected
to the linear actuator via a rack and pinion arrangement, or a
rotary actuator via a spur gear or other connection. For
embodiments comprising a rotary screw-drive configuration where a
larger number of turns would be required, a high reduction gearing
arrangement between the drive member and the sensor, like a worm
and wheel, may be employed.
[0459] In accordance one embodiment of the present disclosure, the
sensor arrangement 7002 for the absolute positioning system 7000
provides a more robust position sensor 7012 for use with surgical
devices. By providing a unique position signal or value for each
possible actuator position, such arrangement eliminates the need
for a zeroing or calibration step and reduces the possibility of
negative design impact in the cases where noise or power brown-out
conditions may create position sense errors as in conventional
rotary encoder configurations.
[0460] In one embodiment, the sensor arrangement 7002 for the
absolute positioning system 7000 replaces conventional rotary
encoders typically attached to the motor rotor and replaces it with
a position sensor 7012 which generates a unique position signal for
each rotational position in a single revolution of a sensor element
associated with the position sensor 7012. Thus, a single revolution
of a sensor element associated with the position sensor 7012 is
equivalent to a longitudinal linear displacement d1 of the of the
longitudinally-movable drive member 1110. In other words, d1 is the
longitudinal linear distance that the longitudinally-movable drive
member 1110 moves from point a to point b after a single revolution
of a sensor element coupled to the longitudinally-movable drive
member 1110. The sensor arrangement 7002 may be connected via a
gear reduction that results in the position sensor 7012 completing
only a single turn for the full stroke of the
longitudinally-movable drive member 1110. With a suitable gear
ratio, the full stroke of the longitudinally-movable drive member
1110 can be represented in one revolution of the position sensor
7012.
[0461] A series of switches 7022a to 7022n, where n is an integer
greater than one, may be employed alone or in combination with gear
reduction to provide a unique position signal for more than one
revolution of the position sensor 7012. The state of the switches
7022a-7022n are fed back to the microcontroller 7004 which applies
logic to determine a unique position signal corresponding to the
longitudinal linear displacement d1+d2+ . . . dn of the
longitudinally-movable drive member 1110.
[0462] Accordingly, the absolute positioning system 7000 provides
an absolute position of the longitudinally-movable drive member
1110 upon power up of the instrument without retracting or
advancing the longitudinally-movable drive member 1110 to a reset
(zero or home) position as may be required with conventional rotary
encoders that merely count the number of steps forwards or
backwards that motor has taken to infer the position of a device
actuator, drive bar, knife, and the like.
[0463] In various embodiments, the position sensor 7012 of the
sensor arrangement 7002 may comprise one or more magnetic sensor,
analog rotary sensor like a potentiometer, array of analog
Hall-effect elements, which output a unique combination of position
signals or values, among others, for example.
[0464] In various embodiments, the microcontroller 7004 may be
programmed to perform various functions such as precise control
over the speed and position of the knife and articulation systems.
Using the known physical properties, the microcontroller 7004 can
be designed to simulate the response of the actual system in the
software of the controller 7004. The simulated response is compared
to (noisy and discrete) measured response of the actual system to
obtain an "observed" response, which is used for actual feedback
decisions. The observed response is a favorable, tuned, value that
balances the smooth, continuous nature of the simulated response
with the measured response, which can detect outside influences on
the system.
[0465] In various embodiments, the absolute positioning system 7000
may further comprise and/or be programmed to implement the
following functionalities. A feedback controller, which can be one
of any feedback controllers, including, but not limited to: PID,
state feedback and adaptive. A power source converts the signal
from the feedback controller into a physical input to the system,
in this case voltage. Other examples include, but are not limited
to pulse width modulated (PWMed) voltage, current and force. The
motor 1102 may be a brushed DC motor with a gearbox and mechanical
links to an articulation or knife system. Other sensor(s) 7018 may
be provided to measure physical parameters of the physical system
in addition to position measured by the position sensor 7012. Since
it is a digital signal (or connected to a digital data acquisition
system) its output will have finite resolution and sampling
frequency. A compare and combine circuit may be provided to combine
the simulated response with the measured response using algorithms
such as, without limitation, weighted average and theoretical
control loop that drives the simulated response towards the
measured response. Simulation of the physical system takes in
account of properties like mass, inertial, viscous friction,
inductance resistance, etc. to predict what the states and outputs
of the physical system will be by knowing the input.
[0466] In one embodiment, the microcontroller 7004 may be an LM
4F230H5QR, available from Texas Instruments, for example. In one
embodiment, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F
Processor Core comprising on-chip memory 7006 of 256 KB
single-cycle flash memory, or other non-volatile memory, up to 40
MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB
single-cycle serial random access memory (SRAM), internal read-only
memory (ROM) loaded with StellarisWare software, 2 KB electrically
erasable programmable read-only memory (EEPROM), two pulse width
modulation (PWM) modules, with a total of 16 advanced PWM outputs
for motion and energy applications, two quadrature encoder inputs
(QEI) analog, two 12-bit Analog-to-Digital Converters (ADC) with 12
analog input channels, among other features that are readily
available for the product datasheet. Other microcontrollers may be
readily substituted for use in the absolute positioning system
7000. Accordingly, the present disclosure should not be limited in
this context.
[0467] In one embodiment, the driver 7010 may be a A3941 available
from Allegro Microsystems, Inc. The A3941 driver 7010 is a
full-bridge controller for use with external N-channel power metal
oxide semiconductor field effect transistors (MOSFETs) specifically
designed for inductive loads, such as brush DC motors. The driver
7010 comprises a unique charge pump regulator provides full (>10
V) gate drive for battery voltages down to 7 V and allows the A3941
to operate with a reduced gate drive, down to 5.5 V. A bootstrap
capacitor may be employed to provide the above-battery supply
voltage required for N-channel MOSFETs. An internal charge pump for
the high-side drive allows DC (100% duty cycle) operation. The full
bridge can be driven in fast or slow decay modes using diode or
synchronous rectification. In the slow decay mode, current
recirculation can be through the high-side or the lowside FETs. The
power FETs are protected from shoot-through by resistor adjustable
dead time. Integrated diagnostics provide indication of
undervoltage, overtemperature, and power bridge faults, and can be
configured to protect the power MOSFETs under most short circuit
conditions. Other motor drivers may be readily substituted for use
in the absolute positioning system 7000. Accordingly, the present
disclosure should not be limited in this context.
[0468] Having described a general architecture for implementing
various embodiments of an absolute positioning system 7000 for a
sensor arrangement 7002, the disclosure now turns to FIGS. 186-192
for a description of one embodiment of a sensor arrangement for the
absolute positioning system 7000. In the embodiment illustrated in
FIG. 186, the sensor arrangement 7002 comprises a magnetic position
sensor 7100, a bipolar magnet 7102 sensor element, a magnet holder
7104 that turns once every full stroke of the
longitudinally-movable drive member 1110 (FIGS. 183-185), and a
gear assembly 7106 to provide a gear reduction. A structural
element such as bracket 7116 is provided to support the gear
assembly 7106, the magnet holder 7104, and the magnet 7102. The
magnetic position sensor 7100 comprises one or more than one
magnetic sensing elements such as Hall elements and is placed in
proximity to the magnet 7102. Accordingly, as the magnet 7102
rotates, the magnetic sensing elements of the magnetic position
sensor 7100 determine the absolute angular position of the magnetic
7102 over one revolution.
[0469] In various embodiments, any number of magnetic sensing
elements may be employed on the absolute positioning system 7000,
such as, for example, magnetic sensors classified according to
whether they measure the total magnetic field or the vector
components of the magnetic field. The techniques used to produce
both types of magnetic sensors encompass many aspects of physics
and electronics. The technologies used for magnetic field sensing
include search coil, fluxgate, optically pumped, nuclear
precession, SQUID, Hall-effect, anisotropic magnetoresistance,
giant magnetoresistance, magnetic tunnel junctions, giant
magnetoimpedance, magnetostrictive/piezoelectric composites,
magnetodiode, magnetotransistor, fiber optic, magnetooptic, and
microelectromechanical systems-based magnetic sensors, among
others.
[0470] In the illustrated embodiment, the gear assembly 7106
comprises a first gear 7108 and a second gear 7110 in meshing
engagement to provide a 3:1 gear ratio connection. A third gear
7112 rotates about shaft 7114. The third gear is in meshing
engagement with the longitudinally-movable drive member 1110 and
rotates in a first direction as the longitudinally-movable drive
member 1110 advances in a distal direction D (FIG. 183) and rotates
in a second direction as the longitudinally-movable drive member
1110 retracts in a proximal direction P (FIG. 183). The second gear
7110 rotates about the same shaft 7114 and therefore, rotation of
the second gear 7110 about the shaft 7114 corresponds to the
longitudinal translation of the longitudinally-movable drive member
1110. Thus, one full stroke of the longitudinally-movable drive
member 1110 in either the distal or proximal directions D, P
corresponds to three rotations of the second gear 7110 and a single
rotation of the first gear 7108. Since the magnet holder 7104 is
coupled to the first gear 7108, the magnet holder 7104 makes one
full rotation with each full stroke of the longitudinally-movable
drive member 1110.
[0471] FIG. 187 is an exploded perspective view of the sensor
arrangement 7002 for the absolute positioning system 7000 showing a
control circuit board assembly 1106 and the relative alignment of
the elements of the sensor arrangement 7002, according to one
embodiment. The position sensor 7100 (not shown in this view) is
supported by a position sensor holder 7118 defining an aperture
7120 suitable to contain the position sensor 7100 is precise
alignment with a rotating magnet 7102 below. The fixture 7120 is
coupled to the bracket 7116 and to the control circuit board
assembly 1106 and remains stationary while the magnet 7102 rotates
with the magnet holder 7104. A hub 7122 is provided to mate with
the first gear 7108/magnet holder 7104 assembly.
[0472] FIGS. 188-190 provide additional views of the sensor
arrangement 7002, according to one embodiment. In particular, FIG.
188 shows the entire sensor arrangement 7002 positioned in
operational mode. The position sensor holder 7118 is located below
the control circuit board assembly 1106 and encapsulates the magnet
holder 7104 and magnet 7102. FIG. 189 shows the magnet 7102 located
below the aperture 7120 defined in the position sensor holder 7118.
The position sensor 7100 and the control circuit board assembly
1106 are not shown for clarity. FIG. 190 shows the sensor
arrangement 7002 with the control circuit board assembly 1106, the
position sensor holder 7118, the position sensor 7100, and the
magnet 7102 removed to show the aperture 7124 that receives the
magnet 7102.
[0473] FIG. 191 is a top view of the sensor arrangement 7002 shown
with the control circuit board 1106 removed but the electronic
components still visible to show the relative position between the
position sensor 7100 and the circuit components 7126, according to
one embodiment. In the embodiment illustrated in connection with
FIGS. 186-191, the gear assembly 7106 composed of first gear 7108
and second gear 7110 have a 3:1 gear ratio such that three
rotations of the second gear 7110 provides a single rotation of the
first gear 7108 and thus the magnet holder 7104. As previously
discussed, the position sensor 7100 remains stationary while the
magnet holder 7104/magnet 7102 assembly rotates.
[0474] As discussed above, a gear assembly can be utilized to drive
the magnet holder 7104 and the magnet 7102. A gear assembly can be
useful in various circumstances as the relative rotation between
one gear in the gear assembly and another gear in the gear assembly
can be reliably predicted. In various other circumstances, any
suitable drive means can be utilized to drive the holder 7104 and
the magnet 7102 so long as the relationship between the output of
the motor and the rotation of the magnet 7102 can be reliably
predicted. Such means can include, for example, a wheel assembly
including at least two contacting wheels, such as plastic wheels
and/or elastomeric wheels, for example, which can transmit motion
therebetween. Such means can also include, for example, a wheel and
belt assembly.
[0475] FIG. 192 is a schematic diagram of one embodiment of a
position sensor 7100 sensor for an absolute positioning system 7000
comprising a magnetic rotary absolute positioning system, according
to one embodiment. In one embodiment, the position sensor 7100 may
be implemented as an AS5055EQFT single-chip magnetic rotary
position sensor available from austriamicrosystems, AG. The
position sensor 7100 is interfaced with the microcontroller 7004 to
provide an absolute positioning system 7000. The position sensor
7100 is a low voltage and low power component and includes four
integrated Hall-effect elements 7128A, 7128B, 7128C, 7128D in an
area 7130 of the position sensor 7100 that is located above the
magnet 7104 (FIGS. 186, 187). A high resolution ADC 7132 and a
smart power management controller 7138 are also provided on the
chip. A CORDIC processor 7136 (for COordinate Rotation DIgital
Computer), also known as the digit-by-digit method and Volder's
algorithm, is provided to implement a simple and efficient
algorithm to calculate hyperbolic and trigonometric functions that
require only addition, subtraction, bitshift, and table lookup
operations. The angle position, alarm bits and magnetic field
information are transmitted over a standard SPI interface 7134 to
the host processor, microcontroller 7004. The position sensor 7100
provides 12 or 14 bits of resolution. In the embodiment illustrated
in FIG. 191, the position sensor 7100 is an AS5055 chip provided in
a small QFN 16-pin 4.times.4.times.0.85 mm package.
[0476] The Hall-effect elements 7128A, 7128B, 7128C, 7128D are
located directly above the rotating magnet. The Hall-effect is a
well known effect and will not be described in detail herein for
the sake of conciseness and clarity of disclosure. Generally, the
Hall-effect is the production of a voltage difference (the Hall
voltage) across an electrical conductor, transverse to an electric
current in the conductor and a magnetic field perpendicular to the
current. It was discovered by Edwin Hall in 1879. The Hall
coefficient is defined as the ratio of the induced electric field
to the product of the current density and the applied magnetic
field. It is a characteristic of the material from which the
conductor is made, since its value depends on the type, number, and
properties of the charge carriers that constitute the current. In
the AS5055 position sensor 7100, the Hall-effect elements 7128A,
7128B, 7128C, 7128D are capable producing a voltage signal that is
indicative of the absolute position of the magnet 7104 (FIGS. 186,
187) in terms of the angle over a single revolution of the magnet
7104. This value of the angle, which is unique position signal, is
calculated by the CORDIC processor 7136 is stored onboard the
AS5055 position sensor 7100 in a register or memory. The value of
the angle that is indicative of the position of the magnet 7104
over one revolution is provided to the host processor 7004 in a
variety of techniques, e.g., upon power up or upon request by the
host processor 7004.
[0477] The AS5055 position sensor 7100 requires only a few external
components to operate when connected to the host microcontroller
7004. Six wires are needed for a simple application using a single
power supply: two wires for power and four wires 7140 for the SPI
serial communication interface 7134 with the host microcontroller
7004. A seventh connection can be added in order to send an
interrupt to the host microcontroller 7004 to inform that a new
valid angle can be read.
[0478] Upon power-up, the AS5055 position sensor 7100 performs a
full power-up sequence including one angle measurement. The
completion of this cycle is indicated as an INT request at output
pin 7142 and the angle value is stored in an internal register.
Once this output is set, the AS5055 position sensor 7100 suspends
to sleep mode. The external microcontroller 7004 can respond to the
INT request at 7142 by reading the angle value from the AS5055
position sensor 7100 over the SPI interface 7134. Once the angle
value is read by the microcontroller 7004, the INT output 7142 is
cleared again. Sending a "read angle" command by the SPI interface
7134 by the microcontroller 7004 to the position sensor 7100 also
automatically powers up the chip and starts another angle
measurement. As soon ad the microcontroller 7004 has completed
reading of the angle value, the INT output 7142 is cleared and a
new result is stored in the angle register. The completion of the
angle measurement is again indicated by setting the INT output 7142
and a corresponding flag in the status register.
[0479] Due to the measurement principle of the AS5055 position
sensor 7100, only a single angle measurement is performed in very
short time (.about.600 .mu.s) after each power-up sequence. As soon
as the measurement of one angle is completed, the AS5055 position
sensor 7100 suspends to power-down state. An on-chip filtering of
the angle value by digital averaging is not implemented, as this
would require more than one angle measurement and consequently, a
longer power-up time which is not desired in low power
applications. The angle jitter can be reduced by averaging of
several angle samples in the external microcontroller 7004. For
example, an averaging of 4 samples reduces the jitter by 6 dB
(50%).
[0480] As discussed above, the motor 1102 positioned within the
handle 1042 of surgical instrument system 1000 can be utilized to
advance and/or retract the firing system of the shaft assembly
1200, including firing members 1272 and 1280, for example, relative
to the end effector 1300 of the shaft assembly 1200 in order to
staple and/or incise tissue captured within the end effector 1300.
In various circumstances, it may be desirable to advance the firing
members 1272 and 1280 at a desired speed, or within a range of
desired speeds. Likewise, it may be desirable to retract the firing
members 1272 and 1280 at a desired speed, or within a range of
desired speeds. In various circumstances, the microcontroller 7004
of the handle 1042, for example, and/or any other suitable
controller, can be configured to control the speed of the firing
members 1272 and 1280. In some circumstances, the controller can be
configured to predict the speed of the firing members 1272 and 1280
based on various parameters of the power supplied to the motor
1102, such as voltage and/or current, for example, and/or other
operating parameters of the motor 1102. The controller can also be
configured to predict the current speed of the firing members 1272
and 1280 based on the previous values of the current and/or voltage
supplied to the motor 1102, and/or previous states of the system
like velocity, acceleration, and/or position. Furthermore, the
controller can also be configured to sense the speed of the firing
members 1272 and 1280 utilizing the absolute positioning sensor
system described above, for example. In various circumstances, the
controller can be configured to compare the predicted speed of the
firing members 1272 and 1280 and the sensed speed of the firing
members 1272 and 1280 to determine whether the power to the motor
1102 should be increased in order to increase the speed of the
firing members 1272 and 1280 and/or decreased in order to decrease
the speed of the firing members 1272 and 1280. U.S. patent
application Ser. No. 12/235,782, entitled MOTOR-DRIVEN SURGICAL
CUTTING INSTRUMENT, now U.S. Pat. No. 8,210,411, is incorporated by
reference in its entirety. U.S. patent application Ser. No.
11/343,803, entitled SURGICAL INSTRUMENT HAVING RECORDING
CAPABILITIES, is incorporated by reference in its entirety.
[0481] Using the physical properties of the instruments disclosed
herein, turning now to FIGS. 198 and 199, a controller, such as
microcontroller 7004, for example, can be designed to simulate the
response of the actual system of the instrument in the software of
the controller. The simulated response is compared to a (noisy and
discrete) measured response of the actual system to obtain an
"observed" response, which is used for actual feedback decisions.
The observed response is a favorable, tuned, value that balances
the smooth, continuous nature of the simulated response with the
measured response, which can detect outside influences on the
system. With regard to FIGS. 198 and 199, a firing element, or
cutting element, in the end effector 1300 of the shaft assembly
1200 can be moved at or near a target velocity, or speed. The
systems disclosed in FIGS. 198 and 199 can be utilized to move the
cutting element at a target velocity. The systems can include a
feedback controller 4200, which can be one of any feedback
controllers, including, but not limited to a PID, a State Feedback,
LQR, and/or an Adaptive controller, for example. The systems can
further include a power source. The power source can convert the
signal from the feedback controller 4200 into a physical input to
the system, in this case voltage, for example. Other examples
include, but are not limited to, pulse width modulated (PWM)
voltage, frequency modulated voltage, current, torque, and/or
force, for example.
[0482] With continued reference to FIGS. 198 and 199, the physical
system referred to therein is the actual drive system of the
instrument configured to drive the firing member, or cutting
member. One example is a brushed DC motor with gearbox and
mechanical links to an articulation and/or knife system. Another
example is the motor 1102 disclosed herein that operates the firing
member 10060 and the articulation driver 10030, for example, of an
interchangeable shaft assembly. The outside influence 4201 referred
to in FIGS. 198 and 199 is the unmeasured, unpredictable influence
of things like tissue, surrounding bodies and friction on the
physical system, for example. Such outside influence can be
referred to as drag and can be represented by a motor 4202 which
acts in opposition to the motor 1102, for example. In various
circumstances, outside influence, such as drag, is the primary
cause for deviation of the simulation of the physical system from
the actual physical system. The systems depicted in FIGS. 198 and
199 and further discussed below can address the differences between
the predicted behavior of the firing member, or cutting member, and
the actual behavior of the firing member, or cutting member.
[0483] With continued reference to FIGS. 198 and 199, the discrete
sensor referred to therein measures physical parameters of the
actual physical system. One embodiment of such a discrete sensor
can include the absolute positioning sensor 7102 and system
described herein. As the output of such a discrete sensor can be a
digital signal (or connected to a digital data acquisition system)
its output may have finite resolution and sampling frequency. The
output of the discrete sensor can be supplied to a microcontroller,
such as microcontroller 7004, for example. In various
circumstances, the microcontroller can combine the simulated, or
estimated, response with the measured response. In certain
circumstances, it may be useful to use enough measured response to
ensure that the outside influence is accounted for without making
the observed response unusably noisy. Examples for algorithms that
do so include a weighted average and/or a theoretical control loop
that drives the simulated response towards the measured response,
for example. Ultimately, further to the above, the simulation of
the physical system takes in account of properties like mass,
inertial, viscous friction, and/or inductance resistance, for
example, to predict what the states and outputs of the physical
system will be by knowing the input. FIG. 199 shows an addition of
evaluating and measuring the current supplied to operate the actual
system, which is yet another parameter that can be evaluated for
controlling the speed of the cutting member, or firing member, of
the shaft assembly 1200, for example. By measuring current in
addition to or in lieu of measuring the voltage, in certain
circumstances, the physical system can be made more accurate.
Nonetheless, the ideas disclosed herein can be extended to the
measurement of other state parameters of other physical
systems.
[0484] Having described various embodiments of an absolute
positioning system 7000 to determine an absolute position
signal/value of a sensor element corresponding to a unique absolute
position of elements associated with articulation and firing, the
disclosure now turns to a description of several techniques for
employing the absolute position/value in a position feedback system
to control the position of the articulation and knife to compensate
for knife band splay in a powered articulated surgical instrument
1010 (FIG. 33). The absolute positioning system 7000 provides a
unique position signal/value to the microcontroller for each
possible location of the drive bar or knife along the length of the
staple cartridge.
[0485] The operation of the articulation joint 1350 has been
described in connection with FIG. 37 and will not be repeated in
detail in this section for conciseness and clarity of disclosure.
The operation of the articulation joint 10090 has been described in
connection with FIG. 102 and will not be repeated in detail in this
section for conciseness and clarity of disclosure. FIG. 193
illustrates an articulation joint 8000 in a straight position,
i.e., at a zero angle .theta..sub.0 relative to the longitudinal
direction depicted as longitudinal axis L-A, according to one
embodiment. FIG. 195 illustrates the articulation joint 8000 of
FIG. 193 articulated in one direction at a first angle
.theta..sub.1 defined between the longitudinal axis L-A and the
articulation axis A-A, according to one embodiment. FIG. 195
illustrates the articulation joint 8000 of FIG. 194 articulated in
another direction at a second angle .theta..sub.2 defined between
the longitudinal axis L-A and the articulation axis A'-A, according
to one embodiment.
[0486] The surgical instrument according to the present disclosure
utilizes multiple flexible knife bands 8002 to transfer compressive
force to a translating a knife element in the cartridge (not shown)
of the end effector 1300 (FIG. 37). The flexible knife bands 8002
enable the end-effector 1300 (FIG. 33) to articulate through a
variety of angles .theta.. The act of articulating, however, causes
the flexible knife bands 8002 to splay. Splay of the flexible knife
bands 8002 changes the effective transection length T.sub.1 in the
longitudinal direction. Thus, it is difficult to determine the
exact position of the knife past the articulation joint 8000 when
the flexible knife bands 8002 are articulated past an angle of
.theta.=0. As previously discussed, the position of the
articulation and knife element can be determined directly using the
absolute position feedback signal/value from the absolute
positioning system 7000 when the articulation angle is zero
.theta..sub.0 as shown in FIG. 194. However, when the flexible
knife bands 8002 deviate from a zero angle .theta..sub.0 from the
longitudinal axis L-A, the absolute position of the knife within
the cartridge cannot be precisely determined based on the absolute
position signal/value provided by the absolute positioning system
7000 to the microcontroller 7004, without knowing the articulation
angle .theta..
[0487] In one embodiment, the articulation angle .theta. can be
determined fairly accurately based on the firing drive of the
surgical instrument. As outlined above, the movement of the firing
member 10060 can be tracked by the absolute positioning system 7000
wherein, when the articulation drive is operably coupled to the
firing member 10060 by the clutch system 10070, for example, the
absolute positioning system 7000 can, in effect, track the movement
of the articulation system via the firing member 10060. As a result
of tracking the movement of the articulation system, the controller
of the surgical instrument can track the articulation angle .theta.
of the end effector, such as end effector 10020, for example. In
various circumstances, as a result, the articulation angle .theta.
can be determined as a function of longitudinal displacement
D.sub.L of the flexible knife bands 8002. Since the longitudinal
displacement D.sub.L of the flexible knife bands 8002 can be
precisely determined based on the absolute position signal/value
provided by the absolute positioning system 7000, an algorithm may
be employed to compensate for the error in displacement of the
knife following the articulation joint 8000.
[0488] In another embodiment, the articulation angle .theta. can be
determined by locating sensors on the flexible knife bands 8002
distal D to the articulation joint 8000. The sensors can be
configured to sense the amount of tension or compression in the
articulated flexible knife bands 8002. The measured tension or
compression results are provided to the microcontroller 7004 to
calculate the articulation angle .theta. based on the amount of
tension or compression measured in the knife bands 8002. Suitable
sensors such as microelectronic mechanical systems (MEMS) devices
and strain gauges may be readily adapted to make such measurements.
Other techniques include locating a tilt sensor, inclinometer,
accelerometer, or any suitable device for measuring angles, in the
articulation joint 8000 to measure the articulation angle
.theta..
[0489] In various embodiments, several techniques for compensating
for splay of the flexible knife bands 8002 in a powered
articulatable surgical instrument 1010 (FIG. 33) are described
hereinbelow in the context of a powered surgical instrument 1010
comprising an absolute positioning system 7000 and a
microcontroller 7004 with data storage capability such as memory
7006.
[0490] FIG. 196 illustrates one embodiment of a logic diagram 8100
for a method of compensating for the effect of splay in flexible
knife bands 8002 on transection length T.sub.1. The method will be
described in connection with FIGS. 185 and 192-196. Accordingly, in
one embodiment of a method 8100 of compensating for the effect of
splay in flexible knife bands 8002 on transection length T.sub.1,
the relationship between articulation angle .theta. of the end
effector 1300 (FIG. 37), or end effector 10020 (FIG. 102), for
example, and effective transection length T.sub.1 distal of the
articulation joint 8000 is initially characterized and the
characterization data is stored in the memory 7006 of the surgical
instrument 1010 (FIG. 33). In one embodiment, the memory 7006 is a
nonvolatile memory such as flash memory, EEPROM, and the like. The
processor 7008 portion of the microcontroller 7004 accesses 8102
the characterization data stored in the memory 7006. The processor
7008 tracks 8104 the articulation angle of the end effector 1300
during use of the surgical instrument 1010. The processor 7008
adjusts 8106 the target transection length T.sub.1 by the surgical
instrument 1010 based on the known articulation angle .theta..sub.M
and the stored characterization data representative of the
relationship between the articulation angle .theta..sub.S and the
transection length T.sub.1.
[0491] In various embodiments, the characterization data
representative of the relationship between the articulation angle
.theta. of the end effector 1300 (FIG. 37) and the effective
transection length T.sub.1 may be completed for the shaft of the
surgical instrument 1010 (FIG. 33) during manufacturing. In one
embodiment, the output of the characterization 8102 process is a
lookup table implemented in the memory 7006. Accordingly, in one
embodiment, the processor 7008 accesses the characterization data
from the lookup table implemented in the memory 7006. In one
aspect, the lookup table comprises an array that replaces runtime
computation with a simpler array indexing operation. The savings in
terms of processing time can be significant, since retrieving a
value from the memory 7006 by the processor 7008 is generally
faster than undergoing an "expensive" computation or input/output
operation. The lookup table may be precalculated and stored in
static program storage, calculated (or "pre-fetched") as part of a
program's initialization phase (memorization), or even stored in
hardware in application-specific platforms. In the instant
application, the lookup table stores the output values of the
characterization of the relationship between articulation angle of
the end effector 1300 (FIG. 37) and effective transection length.
The lookup table stores these output values in an array and, in
some programming languages, may include pointer functions (or
offsets to labels) to process the matching input. Thus, for each
unique value of linear displacement D.sub.L there is a
corresponding articulation angle .theta.. The articulation angle
.theta. is used to calculate a corresponding transection length
T.sub.1 displacement distal the articulation joint 8000, the
articulation joint 1350, or the articulation joint 10090, for
example. The corresponding transection length T.sub.1 displacement
is stored in the lookup table and is used by the microcontroller
7004 to determine the position of the knife past the articulation
joint. Other lookup table techniques are contemplated within the
scope of the present disclosure.
[0492] In one embodiment, the output of the characterization 8102
process is a best curve fit formula, linear or nonlinear.
Accordingly, in one embodiment, the processor 7008 is operative to
execute computer readable instructions to implement a best curve
fit formula based on the characterization data. Curve fitting is
the process of constructing a curve, or mathematical function that
has the best fit to a series of data points, possibly subject to
constraints. Curve fitting can involve either interpolation, where
an exact fit to the data is required. In the instant disclosure,
the curve represents the transection length T.sub.1 displacement of
the flexible knife bands 8002 distal D of the articulated
articulation joint 8000 (FIG. 37) based on the articulation angle
.theta., which depends on the linear displacement D.sub.L of the
flexible knife bands 8002 proximal P to the articulation joint
1350. The data points such as linear displacement D.sub.L of the
flexible knife bands 8002 proximal to the articulation joint 1350,
displacement T.sub.1 of the flexible knife bands 8002 distal the
articulated articulation joint 1350, and articulation angle .theta.
can be measured and used to generate a best fit curve in the form
of an n.sup.th order polynomial (usually a 3.sup.rd order
polynomial would provide a suitable curve fit to the measured
data). The microcontroller 7004 can be programmed to implement the
n.sup.th order polynomial. In use, input the n.sup.th order
polynomial is the linear displacement of the flexible knife bands
8002 derived from the unique absolute position signal/value
provided by the absolute positioning system 7000.
[0493] In one embodiment, the characterization 8102 process
accounts for articulation angle .theta. and compressive force on
the knife bands 8002.
[0494] In one embodiment, the effective transection length is a
distance between the distal most surface of the knife blade in
relationship to a predetermined reference in the handle of the
surgical instruments 1010.
[0495] In various embodiments, the memory 7006 for storing the
characterization may be a nonvolatile memory located on the on the
shaft, the handle, or both, of the surgical instrument 1010 (FIG.
33).
[0496] In various embodiments, the articulation angle .theta. can
be tracked by a sensor located on the shaft of the surgical
instrument 1010 (FIG. 33). In other embodiments, the articulation
angle .theta. can be tracked by a sensor on the handle of the
surgical instrument 1010 or articulation angle .theta. can be
tracked by variables within the control software for the surgical
instrument 1010.
[0497] In one embodiment, the characterization is utilized by
control software of the microcontroller 7004 communicating with the
non-volatile memory 7006 to gain access to the
characterization.
[0498] Various embodiments described herein are described in the
context of staples removably stored within staple cartridges for
use with surgical stapling instruments. In some circumstances,
staples can include wires which are deformed when they contact an
anvil of the surgical stapler. Such wires can be comprised of
metal, such as stainless steel, for example, and/or any other
suitable material. Such embodiments, and the teachings thereof, can
be applied to embodiments which include fasteners removably stored
with fastener cartridges for use with any suitable fastening
instrument.
[0499] Various embodiments described herein are described in the
context of linear end effectors and/or linear fastener cartridges.
Such embodiments, and the teachings thereof, can be applied to
non-linear end effectors and/or non-linear fastener cartridges,
such as, for example, circular and/or contoured end effectors. For
example, various end effectors, including non-linear end effectors,
are disclosed in U.S. patent application Ser. No. 13/036,647, filed
Feb. 28, 2011, entitled SURGICAL STAPLING INSTRUMENT, now U.S.
Patent Application Publication No. 2011/0226837, which is hereby
incorporated by reference in its entirety. Additionally, U.S.
patent application Ser. No. 12/893,461, filed Sep. 29, 2012,
entitled STAPLE CARTRIDGE, now U.S. Patent Application Publication
No. 2012/0074198, is hereby incorporated by reference in its
entirety. U.S. patent application Ser. No. 12/031,873, filed Feb.
15, 2008, entitled END EFFECTORS FOR A SURGICAL CUTTING AND
STAPLING INSTRUMENT, now U.S. Pat. No. 7,980,443, is also hereby
incorporated by reference in its entirety. U.S. Pat. No. 8,393,514,
entitled SELECTIVELY ORIENTABLE IMPLANTABLE FASTENER CARTRIDGE,
which issued on Mar. 12, 2013, is also hereby incorporated by
reference in its entirety.
Examples
[0500] A surgical instrument for treating tissue can comprise a
handle including a trigger, a shaft extending from the handle, an
end effector, and an articulation joint, wherein the end effector
is rotatably coupled to the shaft by the articulation joint. The
surgical instrument can further comprise a firing member operably
coupled with the trigger, wherein the operation of the trigger is
configured to advance the firing member toward the end effector,
and an articulation member operably coupled with the end effector.
The articulation member is selectively engageable with the firing
member such that the articulation member is operably engaged with
the firing member in an engaged configuration and such that the
articulation member is operably disengaged from the firing member
in a disengaged configuration, wherein the firing member is
configured to advance the articulation member toward the end
effector to rotate the end effector about the articulation joint
when the articulation member and the firing member are in the
engaged configuration. The surgical instrument can further include
a biasing member, such as a spring, for example, which can be
configured to re-center the end effector and re-align the end
effector with the shaft along a longitudinal axis after the end
effector has been articulated.
[0501] A surgical instrument for treating tissue can comprise an
electric motor, a shaft, an end effector, and an articulation
joint, wherein the end effector is rotatably coupled to the shaft
by the articulation joint. The surgical instrument can further
comprise a firing drive operably engageable with the electric
motor, wherein the firing drive is configured to be advanced toward
the end effector and retracted away from the end effector by the
electric motor. The surgical instrument can also comprise an
articulation drive operably coupled with the end effector, wherein
the articulation drive is configured to rotate the end effector in
a first direction when the articulation drive is pushed distally
toward the end effector, wherein the articulation drive is
configured to rotate the end effector in a second direction when
the articulation drive is pulled proximally away from the end
effector, wherein the firing drive is selectively engageable with
the articulation drive and is configured to at least one of push
the articulation drive distally toward the end effector and pull
the articulation drive away from the end effector when the firing
drive is operably engaged with the articulation drive, and wherein
the firing drive can operate independently of the articulation
drive when the firing drive is operably disengaged from the
articulation drive.
[0502] A surgical instrument for treating tissue can comprise a
shaft, an end effector rotatably coupled to the shaft, and a firing
member configured to be moved relative to the end effector. The
surgical instrument can further comprise an articulation member
operably coupled with the end effector, wherein the articulation
member is selectively engageable with the firing member such that
the articulation member is operably engaged with the firing member
in an engaged configuration and such that the articulation member
is operably disengaged from the firing member in a disengaged
configuration, and wherein the firing member is configured to move
the articulation member relative to the end effector to rotate the
end effector when the articulation member and the firing member are
in the engaged configuration. The surgical instrument can further
comprise an end effector lock configurable in a locked
configuration and an unlocked configuration, wherein the end
effector lock is configured to operably engage the articulation
member with the firing member when the end effector lock is in the
unlocked configuration.
[0503] A surgical instrument that may include at least one drive
system that is configured to generate control motions and which
defines an actuation axis. The surgical instrument may further
comprise at least one interchangeable shaft assembly that is
configured to be removably coupled to the at least one drive system
in a direction that is substantially transverse to the actuation
axis and transmit the control motions from the at least one drive
system to a surgical end effector operably coupled to the
interchangeable shaft assembly. In addition, the surgical
instrument may further include a lockout assembly that interfaces
with the at least one drive system for preventing actuation of the
drive system unless the at least one interchangeable shaft assembly
has been operably coupled to the at least one drive system.
[0504] A surgical instrument that comprises a shaft assembly that
includes an end effector. The end effector may comprise a surgical
staple cartridge and an anvil that is movably supported relative to
the surgical staple cartridge. The shaft assembly may further
comprise a movable closure shaft assembly that is configured to
apply opening and closing motions to the anvil. A shaft attachment
frame may operably support a portion of the movable closure shaft
assembly thereon. The surgical instrument may further comprise a
frame member that is configured for removable operable engagement
with the shaft attachment frame and a closure drive system that is
operably supported by the frame member and defines an actuation
axis. The closure drive system may be configured for operable
engagement with the closure shaft assembly in a direction that is
substantially transverse to the actuation axis when the shaft
attachment frame is in operable engagement with the frame member. A
lockout assembly may interface with the closure drive system for
preventing actuation of the closure drive system unless the closure
shaft assembly is in operable engagement with the closure drive
system.
[0505] A surgical system that may comprise a frame that operably
supports at least one drive system for generating control motions
upon actuation of a control actuator. At least one of the drive
systems defines an actuation axis. The surgical system may further
comprise a plurality of interchangeable shaft assemblies wherein
each interchangeable shaft assembly may comprise a shaft attachment
frame that is configured to removably operably engage a portion of
the frame in a direction that is substantially transverse to the
actuation axis. A first shaft assembly may be operably supported by
the shaft attachment frame and be configured for operable
engagement with a corresponding one of the at least one drive
systems in the direction that is substantially transverse to the
actuation axis. A lockout assembly may mechanically engage a
portion of the corresponding one of the at least one drive systems
and cooperate with the control actuator to prevent actuation of the
control actuator until the shaft attachment frame is in operable
engagement with the frame portion and the first shaft assembly is
in operable engagement with the one of the at least one drive
systems.
[0506] An interchangeable shaft assembly can be used with a
surgical instrument. In at least one form, the surgical instrument
includes a frame that operably supports a plurality of drive
systems and defines an actuation axis. In one form, the shaft
assembly comprises a first shaft that is configured to apply first
actuation motions to a surgical end effector operably coupled
thereto, wherein a proximal end of the first shaft is configured to
be operably releasably coupled to a first one of the drive systems
supported by the frame in a direction that is substantially
transverse to the actuation axis.
[0507] An interchangeable shaft assembly can be used with a
surgical instrument. In at least one form, the surgical instrument
may include a frame that defines an actuation axis and operably
supports a plurality of drive systems. Various forms of the shaft
assembly may comprise a shaft frame that has a shaft attachment
module attached to a proximal end thereof and is configured to be
releasably coupled to a portion of the frame in a direction that is
substantially transverse to the actuation axis. The shaft assembly
may further comprise an end effector that is operably coupled to a
distal end of the shaft frame. In at least one form, the end
effector comprises a surgical staple cartridge and an anvil that is
movably supported relative to the surgical staple cartridge. The
shaft assembly may further comprise an outer shaft assembly that
includes a distal end that is configured to apply control motions
to the anvil. The outer shaft assembly may include a proximal end
that is configured to be operably releasably coupled to a first one
of the drive systems supported by the frame in a direction that is
substantially transverse to the actuation axis. The shaft assembly
may also comprise a firing shaft assembly that includes a distal
cutting portion that is configured to move between a starting
position and an ending position within the end effector. The firing
shaft assembly may include a proximal end that is configured to be
operably releasably coupled to a firing drive system supported by
the frame in the direction that is substantially transverse to the
actuation axis.
[0508] A surgical system may comprise a frame that supports a
plurality of drive systems and defines an actuation axis. The
system may further comprise a plurality of interchangeable shaft
assemblies. Each interchangeable shaft assembly may comprise an
elongate shaft that is configured to apply first actuation motions
to a surgical end effector operably coupled thereto, wherein a
proximal end of the elongate shaft is configured to be operably
releasably coupled to a first one of the drive systems supported by
the frame in a direction that is substantially transverse to the
actuation axis. Each interchangeable shaft assembly may further
comprise a control shaft assembly that is operably supported within
the elongate shaft and is configured to apply control motions to
the end effector and wherein a proximal end of the control shaft
assembly is configured to be operably releasably coupled to a
second one of the drive systems supported by the frame in the
direction that is substantially transverse to the actuation axis
and wherein at least one of the surgical end effectors differs from
another one of the surgical end effectors.
[0509] Those of ordinary skill in the art will understand that the
various surgical instrument arrangements disclosed herein include a
variety of mechanisms and structures for positive alignment and
positive locking and unlocking of the interchangeable shaft
assemblies to corresponding portion(s) of a surgical instrument,
whether it be a hand-held instrument or a robotically-controlled
instrument. For example, it may be desirable for the instrument to
be configured to prevent actuation of one or more (including all)
of the drive systems at an incorrect time during instrument
preparation or while being used in a surgical procedure.
[0510] A housing for use with a surgical instrument that includes a
shaft and an end effector, wherein the surgical instrument includes
an articulation assembly configured to move the end effector
relative to the shaft. The housing comprises a motor operably
supported by the housing, an articulation drive configured to
transmit at least one articulation motion to the articulation
assembly to move the end effector between an articulation home
state position and an articulated position, a controller in
communication with the motor, a first input configured to transmit
a first input signal to the controller, wherein the controller is
configured to activate the motor to generate the at least one
articulation motion to move the end effector to the articulated
position in response to the first input signal, and a reset input
configured to transmit a reset input signal to the controller,
wherein the controller is configured to activate the motor to
generate at least one reset motion to move the end effector to the
articulation home state position in response to the reset input
signal.
[0511] A surgical instrument comprises a shaft, an end effector
extending distally from the shaft, wherein the end effector is
movable relative to the shaft between an articulation home state
position and an articulated position. The end effector comprises a
staple cartridge including a plurality of staples and a firing
member configured to fire the plurality of staples, wherein the
firing member is movable between a firing home state position and a
fired position. In addition, the surgical instrument comprises a
housing extending proximally from the shaft. The housing comprises
a motor operably supported by the housing, a controller in
communication with the motor, and a home state input configured to
transmit a home state input signal to the controller, wherein the
controller is configured to activate the motor in response to the
home state input signal to effectuate a return of the end effector
to the articulation home state position and a return of the firing
member to the firing home state position.
[0512] A surgical instrument comprises an end effector, a shaft
extending proximally from the end effector, an articulation
assembly configured to move the end effector relative to the shaft
between an unarticulated position, a first articulated position on
a first side of the unarticulated position, and a second
articulated position on a second side of the unarticulated
position, wherein the first side is opposite the second side. In
addition, the surgical instrument further comprises a motor, a
controller in communication with the motor, a first input
configured to transmit a first input signal to the controller,
wherein the controller is configured to activate the motor to move
the end effector to the first articulated position in response to
the first input signal, a second input configured to transmit a
second input signal to the controller, wherein the controller is
configured to activate the motor to move the end effector to the
second articulated position in response to the second input signal,
and a reset input configured to transmit a reset input signal to
the controller, wherein the controller is configured to activate
the motor to move the end effector to the unarticulated position in
response to the reset input signal.
[0513] A surgical instrument comprises an end effector, a shaft
extending proximally from the end effector, a firing assembly
configured to fire a plurality of staples, an articulation assembly
configured to articulate the end effector relative to the shaft, a
locking member movable between a locked configuration and an
unlocked configuration, and a housing extending proximally from the
shaft, wherein the housing is removably couplable to the shaft when
the locking member is in the unlocked configuration. The housing
comprises a motor configured to drive at least one of the firing
assembly and the articulation assembly, and a controller in
communication with the motor, wherein the controller is configured
to activate the motor to reset at least one of the firing assembly
and the articulation assembly to a home state when the locking
member is moved between the locked configuration and the unlocked
configuration.
[0514] A surgical instrument comprises an end effector, a shaft
extending proximally from the end effector, a firing assembly
configured to fire a plurality of staples, an articulation assembly
configured to articulate the end effector relative to the shaft, a
locking member movable between a locked configuration and an
unlocked configuration, and a housing extending proximally from the
shaft, wherein the housing is removably couplable to the shaft when
the locking member is in the unlocked configuration. The housing
comprises a motor configured to drive at least one of the firing
assembly and the articulation assembly, a controller in
communication with the motor, and a home state input operably
coupled to the locking member, wherein the home state input is
configured to transmit a home state input signal to the controller,
and wherein the controller is configured to activate the motor to
reset at least one of the firing assembly and the articulation
assembly to a home state in response to the home state input
signal.
[0515] A surgical instrument comprises an end effector, a shaft
extending proximally from the end effector, an articulation
assembly configured to articulate the end effector relative to the
shaft between a home state position and an articulated position, a
locking member movable between a locked configuration and an
unlocked configuration, and a housing extending proximally from the
shaft, wherein the housing is removably couplable to the shaft when
the locking member is in the unlocked configuration. The housing
comprises a motor configured to drive the articulation assembly,
and a controller in communication with the motor, wherein the
controller is configured to activate the motor to effectuate a
return of the end effector to the home state position when the
locking member is moved between the locked configuration and the
unlocked configuration.
[0516] An absolute position sensor system for a surgical instrument
can comprise, one, a sensor element operatively coupled to a
movable drive member of the surgical instrument and, two, a
position sensor operably coupled to the sensor element, the
position sensor configured to sense the absolute position of the
sensor element.
[0517] A surgical instrument can comprise, one, an absolute
position sensor system comprising a sensor element operatively
coupled to a movable drive member of the surgical instrument and a
position sensor operably coupled to the sensor element, the
position sensor configured to sense the absolute position of the
sensor element and, two, a motor operatively coupled to the movable
drive member.
[0518] An absolute position sensor system for a surgical instrument
can comprise, one, a sensor element operatively coupled to a
movable drive member of the surgical instrument, two, a holder to
hold the sensor element, wherein the holder and the sensor element
are rotationally coupled and, three, a position sensor operably
coupled to the sensor element, the position sensor configured to
sense the absolute position of the sensor element, wherein the
position sensor is fixed relative to the rotation of the holder and
the sensor element.
[0519] A method of compensating for the effect of splay in flexible
knife bands on transection length of a surgical instrument
comprising a processor and a memory, wherein the surgical
instrument comprises stored in the memory characterization data
representative of a relationship between articulation angle of an
end effector and effective transection length distal of an
articulation joint, comprising the steps of, one, accessing, by the
processor, the characterization data from the memory of the
surgical instrument, two, tracking, by the processor, the
articulation angle of the end effector during use of the surgical
instrument and, three, adjusting, by the processor, the target
transection length by the surgical instrument based on the tracked
articulation angle and the stored characterization data.
[0520] A surgical instrument can comprise a microcontroller
comprising a processor configured to execute computer readable
instructions and a memory coupled to the microcontroller, wherein
the processor is operative to, one, access from the memory
characterization data representative of a relationship between
articulation angle of an end effector and effective transection
length distal of an articulation joint, two, track the articulation
angle of the end effector during use of the surgical instrument
and, three, adjust the target transection length based on the
tracked articulation angle and the stored characterization
data.
[0521] A surgical instrument can comprise an end effector
comprising an articulation joint, flexible knife bands configured
to translate from a position proximal of the articulation joint to
a position distal of the articulation joint, a microcontroller
comprising a processor operative to execute computer readable
instructions, and a memory coupled to the microcontroller. The
processor is operative to, one, access from the memory
characterization date representative of a relationship between
articulation angle of an end effector and effective transection
length distal of the articulation joint, two, track the
articulation angle of the end effector during use of the surgical
instrument and, three, adjust the target transection length based
on the known articulation angle and the stored characterization
data.
[0522] A shaft assembly for use with a surgical instrument can
comprise a shaft, an end effector, an articulation joint connecting
the end effector to the shaft, a firing driver movable relative to
the end effector, an articulation driver configured to articulate
the end effector about the articulation joint, and a clutch collar
configured to selectively engage the articulation driver to the
firing driver to impart the movement of the firing driver to the
articulation driver.
[0523] A surgical instrument can comprise a handle, an electric
motor positioned in the handle, a shaft attachable to the handle,
an end effector, an articulation joint connecting the end effector
to the shaft, a firing driver movable toward the end effector,
wherein the electric motor is configured to impart a firing motion
to the firing driver, an articulation driver configured to
articulate the end effector about the articulation joint, and a
rotatable clutch configured to selectively engage the articulation
driver to the firing driver to impart the firing motion to the
articulation driver.
[0524] A shaft assembly for use with a surgical instrument can
comprise a shaft, an end effector, an articulation joint connecting
the end effector to the shaft, a firing driver movable relative to
the end effector, an articulation driver configured to articulate
the end effector about the articulation joint, and a longitudinal
clutch configured to selectively engage the articulation driver to
the firing driver to impart the movement of the firing driver to
the articulation driver.
[0525] A shaft assembly attachable to a handle of a surgical
instrument, the shaft assembly comprising a shaft comprising a
connector portion configured to operably connect the shaft to the
handle, an end effector, an articulation joint connecting the end
effector to the shaft, a firing driver movable relative to the end
effector when a firing motion is applied to the firing driver, an
articulation driver configured to articulate the end effector about
the articulation joint when an articulation motion is applied to
the articulation driver, and an articulation lock configured to
releasably hold the articulation driver in position, wherein the
articulation motion is configured to unlock the articulation
lock.
[0526] A shaft assembly attachable to a handle of a surgical
instrument, the shaft assembly comprising a shaft including, one, a
connector portion configured to operably connect the shaft to the
handle and, two, a proximal end, an end effector comprising a
distal end, an articulation joint connecting the end effector to
the shaft, a firing driver movable relative to the end effector by
a firing motion, an articulation driver configured to articulate
the end effector about the articulation joint when an articulation
motion is applied to the articulation driver, and an articulation
lock comprising, one, a first one-way lock configured to releasably
resist proximal movement of the articulation driver and, two, a
second one-way lock configured to releasably resist distal movement
of the articulation driver.
[0527] A shaft assembly attachable to a handle of a surgical
instrument comprising a shaft including, one, a connector portion
configured to operably connect the shaft to the handle and, two, a
proximal end, an end effector comprising a distal end, an
articulation joint connecting the end effector to the shaft, a
firing driver movable relative to the end effector by a firing
motion, an articulation driver system comprising, one, a proximal
articulation driver and, two, a distal articulation driver operably
engaged with the end effector, and an articulation lock configured
to releasably hold the distal articulation driver in position,
wherein the movement of the proximal articulation driver is
configured to unlock the articulation lock and drive the distal
articulation driver.
[0528] A shaft assembly attachable to a handle of a surgical
instrument comprising a shaft including, one, a connector portion
configured to operably connect the shaft to the handle and, two, a
proximal end, an end effector comprising a distal end, an
articulation joint connecting the end effector to the shaft, a
firing driver movable relative to the end effector by a firing
motion, and an articulation driver system comprising, one, a first
articulation driver and, two, a second articulation driver operably
engaged with the end effector, and an articulation lock configured
to releasably hold the second articulation driver in position,
wherein an initial movement of the first articulation driver is
configured to unlock the second articulation driver and a
subsequent movement of the first articulation driver is configured
to drive the second articulation driver.
[0529] A surgical stapler can comprise a handle, a firing member,
and an electric motor. The electric motor can advance the firing
member during a first operating state, retract the firing member
during a second operating state, and transmit feedback to the
handle during a third operating state. Furthermore, the electric
motor can comprise a shaft and a resonator mounted on the shaft.
The resonator can comprise a body, which can comprise a mounting
hole. The mounting hole and the shaft can be coaxial with a central
axis of the resonator, and the center of mass of the resonator can
be positioned along the central axis. The resonator can also
comprises a spring extending from the body, a weight extending from
the spring, and a counterweight extending from the body.
[0530] A surgical instrument for cutting and stapling tissue can
comprise a handle, a firing member extending from the handle, an
electric motor positioned in the handle, and an amplifier
comprising a center of mass. The electric motor can be configured
to operate in a plurality of states and can comprise a motor shaft.
Furthermore, the amplifier can be mounted to the motor shaft at the
center of mass. The amplifier can rotate in a first direction when
the electric motor is in a firing state, and the amplifier can
oscillate between the first direction and a second direction when
the electric motor is in a feedback state.
[0531] A surgical instrument for cutting and stapling tissue can
comprise holding means for holding the surgical instrument, a
firing member, and motor means for operating in a plurality of
operating states. The plurality of operating states can comprise a
firing state and a feedback state. The motor means can rotate in a
first direction during the firing state and can oscillate between
the first direction and a second direction during the feedback
state. The surgical instrument can further comprise feedback
generating means for generating haptic feedback. The feedback
generating means can be mounted to the motor means.
[0532] A surgical instrument for cutting and stapling tissue can
comprise a handle, a firing member extending from the handle, and
an electric motor positioned in the handle. The electric motor can
be configured to operate in a plurality of states, and the electric
motor can comprise a motor shaft. The surgical instrument can
further comprise a resonator comprising a center of mass. The
resonator can be mounted to the motor shaft at the center of mass.
Furthermore, the resonator can be balanced when the electric motor
is in an advancing state, and the resonator can be unbalanced when
the electric motor is in a feedback state.
[0533] A method for operating a surgical stapler can comprise
initiating an initial operating state. A cutting element can be
driven distally during the initial operating state. The method can
also comprise detecting a threshold condition at the cutting
element, communicating the threshold condition to an operator of
the surgical stapler, and receiving one of a plurality of inputs
from the operator. The plurality of inputs can comprise a first
input and a second input. The method can also comprise initiating a
secondary operating state in response to the input from the
operator. The cutting element can be driven distally in response to
the first input and can be retracted proximally in response to the
second input.
[0534] A method for operating a surgical instrument can comprise
initiating an initial surgical function, detecting a
clinically-important condition, communicating the
clinically-important condition to an operator of the surgical
instrument, accepting an input from the operator, and performing a
secondary surgical function based on the input from the operator.
The secondary surgical function can comprise one of continuing the
initial surgical function or initiating a modified surgical
function.
[0535] A system for controlling a surgical instrument can comprise
a motor, and the motor can drive a firing member during a firing
stroke. The system can also comprise a controller for controlling
the motor, and the controller can be configured to operate in a
plurality of operating states during the firing stroke. The
plurality of operating states can comprise an advancing state and a
retracting state. The system can also comprise a sensor configured
to detect a force on the firing member, wherein the sensor and the
controller can be in signal communication. The controller can pause
the firing stroke when the sensor detects a force on the firing
member that exceeds a threshold force. The system can also comprise
a plurality of input keys, wherein the input keys and the
controller can be in signal communication. The controller can
resume the advancing state when a first input key is activated, and
the controller can initiate the retracting state when a second
input key is activated.
[0536] A surgical instrument can comprise a firing member, a motor
configured to drive the firing member, and a controller for
controlling the motor. The controller can be configured to operate
the surgical instrument in a plurality of operating states, and the
plurality of operating states can comprise a firing state for
driving the firing member and a warned firing state for driving the
firing member. The surgical instrument can also comprise means for
operating the surgical instrument in the warned firing state.
[0537] A surgical instrument can comprise a handle, a shaft
extending from the handle, an end effector, and an articulation
joint connecting the end effector to the shaft. The surgical
instrument can further comprise a firing driver movable relative to
the end effector when a firing motion is applied to the firing
driver, an articulation driver configured to articulate the end
effector about the articulation joint when an articulation motion
is applied to the articulation driver, and an articulation lock
configured to releasably hold the articulation driver in position,
wherein the articulation motion is configured to unlock the
articulation lock.
[0538] A surgical instrument can comprise at least one drive system
configured to generate control motions upon actuation thereof and
defining an actuation axis, at least one interchangeable shaft
assembly configured to be removably coupled to the at least one
drive system in a direction that is substantially transverse to the
actuation axis and transmit the control motions from the at least
one drive system to a surgical end effector operably coupled to
said interchangeable shaft assembly, and a lockout assembly
comprising interfacing means for interfacing with the at least one
drive system and for preventing actuation of the drive system
unless the at least one interchangeable shaft assembly has been
operably coupled to the at least one drive system.
[0539] A surgical instrument including a shaft assembly can
comprise an end effector comprising a surgical staple cartridge and
an anvil, wherein one of the anvil and the surgical staple
cartridge is movable relative to the other of the anvil and the
surgical staple cartridge upon the application of an opening motion
and a closing motion. The surgical instrument can further comprise
a movable closure shaft assembly configured to apply the opening
motion and the closing motion, a shaft attachment frame operably
supporting a portion of the movable closure shaft assembly thereon,
a frame member configured for removable operable engagement with
the shaft attachment frame, a closure drive system operably
supported by the frame member and defining an actuation axis, the
closure drive system configured for operable engagement with the
closure shaft assembly in a direction that is substantially
transverse to the actuation axis when the shaft attachment frame is
in operable engagement with the frame member, and a lockout
assembly interfacing with the closure drive system for preventing
actuation of the closure drive system unless the closure shaft
assembly is in operable engagement with the closure drive
system.
[0540] A surgical instrument can comprise an end effector, a shaft
extending proximally from the end effector, and an articulation
assembly configured to move the end effector relative to the shaft
between an unarticulated position, a first range of articulated
positions on a first side of the unarticulated position, and a
second range of articulated positions on a second side of the
unarticulated position, wherein the first side is opposite the
second side. The surgical instrument can further comprise a motor,
a controller in communication with the motor, a first input
configured to transmit a first input signal to the controller,
wherein the controller is configured to activate the motor to move
the end effector to an articulated position within the first range
of articulated positions in response to the first input signal, a
second input configured to transmit a second input signal to the
controller, wherein the controller is configured to activate the
motor to move the end effector to an articulated position within
the second range of articulated positions in response to the second
input signal and a reset input configured to transmit a reset input
signal to the controller, wherein the controller is configured to
activate the motor to move the end effector to the unarticulated
position in response to the reset input signal.
[0541] While various details have been set forth in the foregoing
description, the various embodiments may be practiced without these
specific details. For example, for conciseness and clarity selected
aspects have been shown in block diagram form rather than in
detail. Some portions of the detailed descriptions provided herein
may be presented in terms of instructions that operate on data that
is stored in a computer memory. Such descriptions and
representations are used by those skilled in the art to describe
and convey the substance of their work to others skilled in the
art. In general, an algorithm refers to a self-consistent sequence
of steps leading to a desired result, where a "step" refers to a
manipulation of physical quantities which may, though need not
necessarily, take the form of electrical or magnetic signals
capable of being stored, transferred, combined, compared, and
otherwise manipulated. It is common usage to refer to these signals
as bits, values, elements, symbols, characters, terms, numbers, or
the like. These and similar terms may be associated with the
appropriate physical quantities and are merely convenient labels
applied to these quantities.
[0542] Unless specifically stated otherwise as apparent from the
foregoing discussion, it is appreciated that, throughout the
foregoing description, discussions using terms such as "processing"
or "computing" or "calculating" or "determining" or "displaying" or
the like, refer to the action and processes of a computer system,
or similar electronic computing device, that manipulates and
transforms data represented as physical (electronic) quantities
within the computer system's registers and memories into other data
similarly represented as physical quantities within the computer
system memories or registers or other such information storage,
transmission or display devices.
[0543] In a general sense, those skilled in the art will recognize
that the various aspects described herein which can be implemented,
individually and/or collectively, by a wide range of hardware,
software, firmware, or any combination thereof can be viewed as
being composed of various types of "electrical circuitry."
Consequently, as used herein "electrical circuitry" includes, but
is not limited to, electrical circuitry having at least one
discrete electrical circuit, electrical circuitry having at least
one integrated circuit, electrical circuitry having at least one
application specific integrated circuit, electrical circuitry
forming a general purpose computing device configured by a computer
program (e.g., a general purpose computer configured by a computer
program which at least partially carries out processes and/or
devices described herein, or a microprocessor configured by a
computer program which at least partially carries out processes
and/or devices described herein), electrical circuitry forming a
memory device (e.g., forms of random access memory), and/or
electrical circuitry forming a communications device (e.g., a
modem, communications switch, or optical-electrical equipment).
Those having skill in the art will recognize that the subject
matter described herein may be implemented in an analog or digital
fashion or some combination thereof.
[0544] The foregoing detailed description has set forth various
embodiments of the devices and/or processes via the use of block
diagrams, flowcharts, and/or examples. Insofar as such block
diagrams, flowcharts, and/or examples contain one or more functions
and/or operations, it will be understood by those within the art
that each function and/or operation within such block diagrams,
flowcharts, or examples can be implemented, individually and/or
collectively, by a wide range of hardware, software, firmware, or
virtually any combination thereof. In one embodiment, several
portions of the subject matter described herein may be implemented
via Application Specific Integrated Circuits (ASICs), Field
Programmable Gate Arrays (FPGAs), digital signal processors (DSPs),
or other integrated formats. However, those skilled in the art will
recognize that some aspects of the embodiments disclosed herein, in
whole or in part, can be equivalently implemented in integrated
circuits, as one or more computer programs running on one or more
computers (e.g., as one or more programs running on one or more
computer systems), as one or more programs running on one or more
processors (e.g., as one or more programs running on one or more
microprocessors), as firmware, or as virtually any combination
thereof, and that designing the circuitry and/or writing the code
for the software and or firmware would be well within the skill of
one of skill in the art in light of this disclosure. In addition,
those skilled in the art will appreciate that the mechanisms of the
subject matter described herein are capable of being distributed as
a program product in a variety of forms, and that an illustrative
embodiment of the subject matter described herein applies
regardless of the particular type of signal bearing medium used to
actually carry out the distribution. Examples of a signal bearing
medium include, but are not limited to, the following: a recordable
type medium such as a floppy disk, a hard disk drive, a Compact
Disc (CD), a Digital Video Disk (DVD), a digital tape, a computer
memory, etc.; and a transmission type medium such as a digital
and/or an analog communication medium (e.g., a fiber optic cable, a
waveguide, a wired communications link, a wireless communication
link (e.g., transmitter, receiver, transmission logic, reception
logic, etc.), etc.).
[0545] One skilled in the art will recognize that the herein
described components (e.g., operations), devices, objects, and the
discussion accompanying them are used as examples for the sake of
conceptual clarity and that various configuration modifications are
contemplated. Consequently, as used herein, the specific exemplars
set forth and the accompanying discussion are intended to be
representative of their more general classes. In general, use of
any specific exemplar is intended to be representative of its
class, and the non-inclusion of specific components (e.g.,
operations), devices, and objects should not be taken limiting.
[0546] With respect to the use of substantially any plural and/or
singular terms herein, those having skill in the art can translate
from the plural to the singular and/or from the singular to the
plural as is appropriate to the context and/or application. The
various singular/plural permutations are not expressly set forth
herein for sake of clarity.
[0547] The herein described subject matter sometimes illustrates
different components contained within, or connected with, different
other components. It is to be understood that such depicted
architectures are merely exemplary, and that in fact many other
architectures may be implemented which achieve the same
functionality. In a conceptual sense, any arrangement of components
to achieve the same functionality is effectively "associated" such
that the desired functionality is achieved. Hence, any two
components herein combined to achieve a particular functionality
can be seen as "associated with" each other such that the desired
functionality is achieved, irrespective of architectures or
intermedial components. Likewise, any two components so associated
can also be viewed as being "operably connected," or "operably
coupled," to each other to achieve the desired functionality, and
any two components capable of being so associated can also be
viewed as being "operably couplable," to each other to achieve the
desired functionality. Specific examples of operably couplable
include but are not limited to physically mateable and/or
physically interacting components, and/or wirelessly interactable,
and/or wirelessly interacting components, and/or logically
interacting, and/or logically interactable components.
[0548] In some instances, one or more components may be referred to
herein as "configured to," "configurable to," "operable/operative
to," "adapted/adaptable," "able to," "conformable/conformed to,"
etc. Those skilled in the art will recognize that "configured to"
can generally encompass active-state components and/or
inactive-state components and/or standby-state components, unless
context requires otherwise.
[0549] With respect to the appended claims, those skilled in the
art will appreciate that recited operations therein may generally
be performed in any order. Also, although various operational flows
are presented in a sequence(s), it should be understood that the
various operations may be performed in other orders than those
which are illustrated, or may be performed concurrently. Examples
of such alternate orderings may include overlapping, interleaved,
interrupted, reordered, incremental, preparatory, supplemental,
simultaneous, reverse, or other variant orderings, unless context
dictates otherwise. Furthermore, terms like "responsive to,"
"related to," or other past-tense adjectives are generally not
intended to exclude such variants, unless context dictates
otherwise.
[0550] Although various embodiments have been described herein,
many modifications, variations, substitutions, changes, and
equivalents to those embodiments may be implemented and will occur
to those skilled in the art. Also, where materials are disclosed
for certain components, other materials may be used. It is
therefore to be understood that the foregoing description and the
appended claims are intended to cover all such modifications and
variations as falling within the scope of the disclosed
embodiments. The following claims are intended to cover all such
modification and variations.
[0551] The disclosure of U.S. Patent Application Publication No.
2010/0264194, entitled SURGICAL STAPLING INSTRUMENT WITH AN
ARTICULATABLE END EFFECTOR, filed on Apr. 22, 2010, is incorporated
herein by reference in its entirety. The disclosure of U.S. patent
application Ser. No. 13/524,049, entitled ARTICULATABLE SURGICAL
INSTRUMENT COMPRISING A FIRING DRIVE, filed on Jun. 15, 2012, is
incorporated herein by reference in its entirety.
[0552] The devices disclosed herein can be designed to be disposed
of after a single use, or they can be designed to be used multiple
times. In either case, however, the device can be reconditioned for
reuse after at least one use. Reconditioning can include any
combination of the steps of disassembly of the device, followed by
cleaning or replacement of particular pieces, and subsequent
reassembly. In particular, the device can be disassembled, and any
number of the particular pieces or parts of the device can be
selectively replaced or removed in any combination. Upon cleaning
and/or replacement of particular parts, the device can be
reassembled for subsequent use either at a reconditioning facility,
or by a surgical team immediately prior to a surgical procedure.
Those skilled in the art will appreciate that reconditioning of a
device can utilize a variety of techniques for disassembly,
cleaning/replacement, and reassembly. Use of such techniques, and
the resulting reconditioned device, are all within the scope of the
present application.
[0553] Preferably, the invention described herein will be processed
before surgery. First, a new or used instrument is obtained and if
necessary cleaned. The instrument can then be sterilized. In one
sterilization technique, the instrument is placed in a closed and
sealed container, such as a plastic or TYVEK bag. The container and
instrument are then placed in a field of radiation that can
penetrate the container, such as gamma radiation, x-rays, or
high-energy electrons. The radiation kills bacteria on the
instrument and in the container. The sterilized instrument can then
be stored in the sterile container. The sealed container keeps the
instrument sterile until it is opened in the medical facility.
[0554] Any patent, publication, or other disclosure material, in
whole or in part, that is said to be incorporated by reference
herein is incorporated herein only to the extent that the
incorporated materials does not conflict with existing definitions,
statements, or other disclosure material set forth in this
disclosure. As such, and to the extent necessary, the disclosure as
explicitly set forth herein supersedes any conflicting material
incorporated herein by reference. Any material, or portion thereof,
that is said to be incorporated by reference herein, but which
conflicts with existing definitions, statements, or other
disclosure material set forth herein will only be incorporated to
the extent that no conflict arises between that incorporated
material and the existing disclosure material.
[0555] In summary, numerous benefits have been described which
result from employing the concepts described herein. The foregoing
description of the one or more embodiments has been presented for
purposes of illustration and description. It is not intended to be
exhaustive or limiting to the precise form disclosed. Modifications
or variations are possible in light of the above teachings. The one
or more embodiments were chosen and described in order to
illustrate principles and practical application to thereby enable
one of ordinary skill in the art to utilize the various embodiments
and with various modifications as are suited to the particular use
contemplated. It is intended that the claims submitted herewith
define the overall scope.
* * * * *