U.S. patent application number 13/974206 was filed with the patent office on 2015-02-26 for torque optimization for surgical instruments.
This patent application is currently assigned to Ethicon Endo-Surgery, Inc.. The applicant listed for this patent is Ethicon Endo-Surgery, Inc.. Invention is credited to Emily A. Schellin, Frederick E. Shelton, IV, Jeffrey S. Swayze, David C. Yates.
Application Number | 20150053746 13/974206 |
Document ID | / |
Family ID | 55968844 |
Filed Date | 2015-02-26 |
United States Patent
Application |
20150053746 |
Kind Code |
A1 |
Shelton, IV; Frederick E. ;
et al. |
February 26, 2015 |
TORQUE OPTIMIZATION FOR SURGICAL INSTRUMENTS
Abstract
A control system having speed management control. The control
system can be in signal communication with a battery, and the
battery can be coupled to a motor. The speed management control can
include a pulse width modulation circuit, which can control the
duration of pulses supplied from the battery to the motor. The
motor can include a primary set of coils and a secondary set of
coils. The control system can direct surplus current to the
secondary set of coils to maximize the torque generated by the
motor.
Inventors: |
Shelton, IV; Frederick E.;
(Hillsboro, OH) ; Yates; David C.; (West Chester,
OH) ; Schellin; Emily A.; (Cincinnati, OH) ;
Swayze; Jeffrey S.; (Hamilton, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ethicon Endo-Surgery, Inc. |
Cincinnati |
OH |
US |
|
|
Assignee: |
Ethicon Endo-Surgery, Inc.
Cincinnati
OH
|
Family ID: |
55968844 |
Appl. No.: |
13/974206 |
Filed: |
August 23, 2013 |
Current U.S.
Class: |
227/177.1 |
Current CPC
Class: |
A61B 2017/07271
20130101; A61B 90/96 20160201; A61B 2017/00119 20130101; A61B
2017/00398 20130101; A61B 2019/4873 20130101; A61B 19/5225
20130101; A61B 2017/00221 20130101; A61B 2017/00123 20130101; A61B
2034/256 20160201; A61B 34/10 20160201; A61B 2019/5229 20130101;
G06F 3/04845 20130101; G06T 11/60 20130101; H03K 2217/96062
20130101; A61B 17/105 20130101; A61B 2017/00084 20130101; A61B
2017/2927 20130101; G16Z 99/00 20190201; A61B 90/90 20160201; A61B
2017/00367 20130101; G06F 3/0416 20130101; G06F 3/0482 20130101;
A61B 2017/2901 20130101; A61B 2090/0811 20160201; H02J 7/0068
20130101; A61B 2017/00137 20130101; H02J 7/342 20200101; A61B 90/03
20160201; A61B 2019/564 20130101; H01M 10/425 20130101; A61B
2017/07278 20130101; H01M 10/48 20130101; A61B 17/068 20130101;
A61B 90/98 20160201; A61B 2017/2923 20130101; A61B 2019/442
20130101; H01M 2220/30 20130101; A61B 34/30 20160201; G06F 21/60
20130101; A61B 17/07207 20130101; A61B 2017/07257 20130101; A61B
2019/305 20130101; A61B 2019/4815 20130101; A61B 2090/037 20160201;
G06F 3/0488 20130101; Y02E 60/10 20130101; A61B 2560/0214 20130101;
G06F 19/3406 20130101; G16H 20/40 20180101; A61B 2017/291 20130101;
A61B 2017/0046 20130101; A61B 2017/07228 20130101; A61B 2090/0814
20160201; A61B 2017/00486 20130101; A61B 2017/07214 20130101; G16H
40/63 20180101; A61B 2019/448 20130101; A61B 2017/00115 20130101;
A61B 2017/00154 20130101; A61B 2017/07285 20130101; A61B 2017/00734
20130101; A61B 2017/2946 20130101; A61B 2034/252 20160201; A61B
2090/035 20160201; A61B 17/072 20130101; A61B 2017/00402 20130101;
A61B 2017/00477 20130101; A61B 2090/0803 20160201; A61B 2090/0804
20160201; H02J 9/061 20130101; A61B 2017/0019 20130101; A61B
2017/00473 20130101; A61B 2019/4857 20130101; A61B 34/25 20160201;
A61B 34/74 20160201; A61B 2017/2941 20130101; A61B 17/00234
20130101; A61B 34/76 20160201; A61B 2017/00407 20130101; A61B
2019/4836 20130101; A61B 2090/0807 20160201; G09G 5/14 20130101;
A61B 2017/00017 20130101; A61B 2017/00464 20130101; A61B 2017/2929
20130101; A61B 2090/0808 20160201; G06F 3/016 20130101; H02J
2310/23 20200101; A61B 2017/00199 20130101; A61B 2017/00482
20130101; H01M 2/34 20130101; G06F 3/04817 20130101; H02J 7/00
20130101 |
Class at
Publication: |
227/177.1 |
International
Class: |
A61B 17/072 20060101
A61B017/072 |
Claims
1. A surgical stapler, comprising: an end effector comprising a
plurality of deployable staples and a firing element; a motor
configured to drive said firing element, wherein said motor
comprises a primary set of coils and a secondary set of coils; and
a control system in signal communication with said motor, wherein
said control system comprises: a battery; a pulse width modulation
circuit configured to control the duration of current pulses
supplied from said battery to said motor; and a switch configured
to switch the electric motor between a plurality of operating
states, wherein the plurality of operating states comprises: a
first operating state in which the primary set of coils are
configured to drive said firing element; and a second operating
state in which said primary set of coils and said secondary set of
coils are configured to drive said firing element.
2. The surgical stapler of claim 1, wherein the battery supplies
current pulses to said primary set of coils at a voltage that
corresponds to the maximum torque of said primary set of coils
during the first operating state.
3. The surgical stapler of claim 2, wherein a surplus current is
supplied to said secondary set of coils during the second operating
state.
4. The surgical stapler of claim 3, wherein said control system
maximizes the surplus current supplied to said secondary set of
coils during the second operating state based on the volt-ampere
limit of said battery.
5. The surgical instrument of claim 1, wherein said motor generates
a first amount of torque during the first operating state, wherein
said motor generates a second amount of torque during the second
operating state, and wherein the second amount of torque is greater
than the first amount of torque.
6. The surgical stapler of claim 5, wherein said motor drives said
firing element in a first direction during the first operating
state, wherein said motor drives said firing element in a second
direction during the second operating state, and wherein the second
direction is opposite to the first direction.
7. The surgical stapler of claim 6, wherein the first direction
comprises a distally advancing direction, and wherein the second
direction comprises a proximally retracting direction.
8. The surgical stapler of claim 1, wherein said motor comprises a
stepper motor.
9. A surgical stapler, comprising: an end effector comprising a
plurality of deployable staples and a firing element; a control
system, comprising: a battery; and a pulse width modulation circuit
configured to control the duration of current pulses supplied from
said battery; and a motor in signal communication with said control
system and configured to drive said firing element, wherein said
motor comprises: a primary set of coils configured to generate a
first amount of torque, wherein the first amount of torque drives
said firing element in a first direction; and a secondary set of
coils configured to generate a second amount of torque, wherein the
first amount of torque and the second amount of torque drive said
firing element in a second direction.
10. The surgical stapler of claim 9, wherein said battery is
configured to supply current pulses to said primary set of coils at
a voltage that corresponds to the maximum torque of said primary
set of coils.
11. The surgical stapler of claim 10, wherein said battery operably
supplies a surplus current to said secondary set of coils.
12. The surgical stapler of claim 9, wherein said control system
maximizes the torque generated by said primary set of coils and the
secondary set of coils when driving said firing element in the
second direction.
13. The surgical stapler of claim 9, wherein the second direction
is opposite to the first direction.
14. The surgical stapler of claim 5, wherein the second direction
comprises a proximal direction.
15. The surgical stapler of claim 1, wherein said motor comprises a
stepper motor.
16. A surgical stapler, comprising: an end effector comprising a
plurality of deployable staples and a firing element; a motor
configured to drive said firing element, wherein said motor
comprises a primary set of coils; and a control system in signal
communication with said motor, wherein said control system
comprises: a battery; and a pulse width modulation circuit
configured to control the duration of current pulses supplied from
said battery to said primary set of coils.
17. The surgical stapler of claim 16, wherein said motor further
comprises a secondary set of coils, and wherein said control system
comprises a switch configured to operably supply current from said
battery to said secondary set of coils.
18. The surgical stapler of claim 17, wherein said battery supplies
current to said primary set of coils during a first operating
state, and wherein said battery supplies current to said primary
set of coils and said secondary set of coils during a second
operating state.
19. The surgical stapler of claim 18, wherein said motor drives
said firing element distally during the first operating state, and
wherein said motor drives said firing element proximally during the
second operating state.
20. The surgical stapler of claim 16, wherein said control system
optimizes the torque generated by said motor.
21. The surgical stapler of claim 16, wherein said motor comprises
a stepper motor.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to surgical instruments and,
in various arrangements, to powered surgical cutting and stapling
instruments and staple cartridges therefor that are designed to cut
and staple tissue.
BACKGROUND
[0002] Surgical staplers are often used to deploy staples into soft
tissue to reduce or eliminate bleeding from the soft tissue,
especially as the tissue is being transected, for example. Surgical
staplers, such as an endocutter, for example, can comprise an end
effector which can be moved, or articulated, with respect to an
elongated shaft assembly. End effectors are often configured to
secure soft tissue between first and second jaw members where the
first jaw member often includes a staple cartridge which is
configured to removably store staples therein and the second jaw
member often includes an anvil. Such surgical staplers can include
a closing system for pivoting the anvil relative to the staple
cartridge.
[0003] Surgical staplers, as outlined above, can be configured to
pivot the anvil of the end effector relative to the staple
cartridge in order to capture soft tissue therebetween. In various
circumstances, the anvil can be configured to apply a clamping
force to the soft tissue in order to hold the soft tissue tightly
between the anvil and the staple cartridge. If a surgeon is
unsatisfied with the position of the end effector, however, the
surgeon must typically activate a release mechanism on the surgical
stapler to pivot the anvil into an open position and then
reposition the end effector. Thereafter, staples are typically
deployed from the staple cartridge by a driver which traverses a
channel in the staple cartridge and causes the staples to be
deformed against the anvil and secure layers of the soft tissue
together. Often, as known in the art, the staples are deployed in
several staple lines, or rows, in order to more reliably secure the
layers of tissue together. The end effector may also include a
cutting member, such as a knife, for example, which is advanced
between two rows of the staples to resect the soft tissue after the
layers of the soft tissue have been stapled together.
[0004] Such surgical staplers and effectors may be sized and
configured to be inserted into a body cavity through a trocar or
other access opening. The end effector is typically coupled to an
elongated shaft that is sized to pass through the trocar or
opening. The elongated shaft assembly is often operably coupled to
a handle that supports control systems and/or triggers for
controlling the operation of the end effector. To facilitate proper
location and orientation of the end effector within the body, many
surgical instruments are configured to facilitate articulation of
the end effector relative to a portion of the elongated shaft.
[0005] Powered surgical instruments are disclosed in U.S. Patent
Application Publication No. US 2009/0090763 A1, entitled POWERED
SURGICAL STAPLING DEVICE to Zemlok et al. (hereinafter "Zemlok
'763"), the entire disclosure of which is hereby incorporated by
reference herein. Powered surgical instruments are also disclosed
in U.S. Patent Application Publication No. US 2011/0278344 A1,
entitled POWERED SURGICAL INSTRUMENT to Zemlok et al. (hereinafter
"Zemlok '344"), now U.S. Pat. No. 8,201,721, the entire disclosure
of which is hereby incorporated by reference herein.
[0006] The foregoing discussion is intended only to illustrate
various aspects of the related art in the field of the invention at
the time, and should not be taken as a disavowal of claim
scope.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] 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:
[0008] FIG. 1 is a perspective view of a surgical instrument
employing one form of retraction arrangement;
[0009] FIG. 2 is a perspective view of an exemplary loading unit
that may be employed in connection with various surgical
instruments disclosed herein;
[0010] FIG. 3 is an exploded perspective view of a portion of the
loading unit depicted in FIG. 2;
[0011] FIG. 4 is a top view of a portion of the surgical instrument
of FIG. 1;
[0012] FIG. 5 is a partial side view of a portion of the surgical
instrument depicted in FIG. 4 with the clutch assembly in a
disengaged position;
[0013] FIG. 6 is a top view of a portion of a retraction assembly
embodiment and retraction lever arrangement thereof;
[0014] FIG. 7 is a partial exploded view of one form of a drive
unit with portions thereof shown in cross-section;
[0015] FIG. 8 is another top view of a portion of the surgical
instrument with the drive unit locking system in the locked
position;
[0016] FIG. 9 is a top view of one form of a locking pawl
assembly;
[0017] FIG. 10 is a side elevational view of the locking pawl
assembly of FIG. 9;
[0018] FIG. 11 is a bottom view of the locking pawl assembly of
FIGS. 9 and 10;
[0019] FIG. 12 is a front view of a gear box housing
embodiment;
[0020] FIG. 13 is a partial side cross-sectional view of a surgical
instrument embodiment with portions thereof shown in cross-section
and with the drive unit locking system in a locked orientation;
[0021] FIG. 14 is another partial side cross-sectional view of the
surgical instrument of FIG. 13 with the drive unit locking system
in an unlocked orientation;
[0022] FIG. 15 is a top view of another surgical instrument
embodiment with a portion of the housing removed to expose a
portion of the instrument's drive unit locking system
arrangement;
[0023] FIG. 16 is a partial side cross-sectional view of the
surgical instrument embodiment of FIG. 15 with portions thereof
shown in cross-section and with solid lines illustrating the drive
unit locking system in a locked orientation and with broken lines
illustrating the drive unit locking system in an unlocked
orientation;
[0024] FIG. 17 is another partial top view of the surgical
instrument embodiment of FIGS. 15 and 16 with solid lines
illustrating the position of the retraction lever prior to
actuation and broken lines illustrating the position of the
retraction lever after initial actuation;
[0025] FIG. 18 is another partial top view of the surgical
instrument embodiment of FIGS. 15-17 with broken lines illustrating
the retraction lever in a fully actuated position;
[0026] FIG. 19 is a partial top view of a portion of another
surgical instrument embodiment with a portion of the housing
omitted to expose the instrument's drive unit locking system and
with solid lines depicting the retraction lever in an un-actuated
position and broken lines illustrating the retraction lever after
initial actuation;
[0027] FIG. 20 is a partial top view of another surgical instrument
embodiment with a portion of the housing omitted to expose the
drive unit locking system thereof in a locked orientation;
[0028] FIG. 21 is another partial top view of the surgical
instrument embodiment of FIG. 20 with the drive unit locking system
in an unlocked orientation;
[0029] FIG. 22 is a partial cross-sectional side view of a portion
of a surgical instrument and end effector with the retraction
assembly thereof in an unactuated orientation;
[0030] FIG. 23 is another partial cross-sectional side view of the
surgical instrument and end effector of FIG. 22 after the firing
rod assembly has been fired;
[0031] FIG. 24 is another partial cross-sectional side view of the
surgical instrument and end effector of FIG. 23 and after the
retraction assembly has been actuated to retract the drive beam
back to its starting position within the end effector;
[0032] FIG. 25 is a partial cross-sectional side view of a portion
of another surgical instrument and end effector in a prefire
condition and with the retraction assembly thereof in an unactuated
orientation;
[0033] FIG. 26 is another partial cross-sectional side view of the
surgical instrument and end effector of FIG. 25 after firing;
[0034] FIG. 27 is another partial cross-sectional side view of the
surgical instrument and end effector of FIG. 26 with the latch of
the retraction assembly thereof in an unlatched orientation;
[0035] FIG. 28 is another partial cross-sectional side view of the
surgical instrument and end effector of FIG. 27 with the distal
firing rod portion in a retracted orientation;
[0036] FIG. 29 is a partial cross-sectional view of a portion of
another surgical instrument embodiment with the drive coupler
assembly thereof in an articulation orientation;
[0037] FIG. 30 is a partial cross-sectional view of a portion of
the surgical instrument embodiment of FIG. 29 with the drive
coupler assembly thereof in a firing orientation;
[0038] FIG. 31 is an enlarged cross-sectional view of the drive
coupler assembly of the surgical instrument of FIGS. 29 and 30 with
the coupler selector member shown in solid lines in the
articulation orientation and with the coupler selector member shown
in broken lines in a firing orientation;
[0039] FIG. 32 is a partial cross-sectional view of a portion of
another surgical instrument embodiment;
[0040] FIG. 33 is an enlarged partial cross-sectional view of a
portion of the surgical instrument of FIG. 32;
[0041] FIG. 34 is another enlarged partial cross-sectional view of
a portion of the surgical instrument of FIGS. 32 and 33 with the
travel limiter thereof in its distal-most orientation;
[0042] FIG. 35 is another enlarged partial cross-sectional view of
a portion of the surgical instrument of FIGS. 32-34 with the travel
limiter thereof in its proximal-most orientation;
[0043] FIG. 36 is a partial cross-sectional view of the surgical
instrument of FIG. 33 taken along line 36-36 in FIG. 33;
[0044] FIG. 37 is a partial perspective view of a portion of the
surgical instrument of FIGS. 32-36;
[0045] FIG. 38 is a partial perspective view of a shaft of a
surgical instrument, a collar, and a disposable loading unit
unattached to the shaft according to various embodiments of the
present disclosure;
[0046] FIG. 39 is a partial perspective view of the shaft, the
collar and the disposable loading unit of FIG. 38, depicting the
disposable loading unit attached to the shaft;
[0047] FIG. 40 is a partial exploded perspective view of the shaft,
the collar, and the disposable loading unit of FIG. 38;
[0048] FIG. 41 is another partial exploded perspective view of the
shaft, the collar, and the disposable loading unit of FIG. 38;
[0049] FIG. 42 is a perspective view of a distal attachment portion
of the disposable loading unit of FIG. 38;
[0050] FIG. 43 is another perspective view of the distal attachment
portion of the disposable loading unit of FIG. 38;
[0051] FIG. 44 is a perspective view of a proximal attachment
portion of the shaft of FIG. 38;
[0052] FIG. 45 is another perspective view of the proximal
attachment portion of the shaft of FIG. 38;
[0053] FIG. 46 is a perspective view of the collar and a firing
shaft of the surgical instrument of FIG. 38;
[0054] FIG. 47 is a partial perspective, cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit attached to the shaft;
[0055] FIG. 48 is a partial elevation, cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit unattached to the shaft;
[0056] FIG. 49 is a partial elevation, cross-section view of the
disposable loading unit, the collar and the shaft of FIG. 38,
depicting the disposable loading unit attached to the shaft;
[0057] FIG. 50 is an elevation view of the collar and the shaft of
FIG. 38 taken along the plane indicated in FIG. 48;
[0058] FIG. 51 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit unattached to the shaft, and
further depicting the collar in an initial orientation relative to
the shaft;
[0059] FIG. 52 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit unattached to the shaft, and
further depicting the collar in the initial orientation relative to
the shaft;
[0060] FIG. 53 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit entering the shaft, and
further depicting the collar in the initial orientation relative to
the shaft;
[0061] FIG. 54 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit entering the shaft, and
further depicting the collar in a secondary, rotated orientation
relative to the shaft;
[0062] FIG. 55 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit entering the shaft, and
further depicting the collar in the secondary, rotated orientation
relative to the shaft;
[0063] FIG. 56 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit fully inserted into the
shaft, and further depicting the collar in the secondary, rotated
orientation relative to the shaft;
[0064] FIG. 57 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit fully inserted into the
shaft, and further depicting the collar in the initial orientation
relative to the shaft;
[0065] FIG. 58 is a perspective, partial cross-section view of the
disposable loading unit, the collar, and the shaft of FIG. 38,
depicting the disposable loading unit fully inserted into the
shaft, and further depicting the collar in the initial orientation
relative to the shaft;
[0066] FIG. 59 is a partial, perspective, cross-section view of a
shaft of a surgical instrument and a disposable loading unit
unattached to the shaft according to various embodiments of the
present disclosure;
[0067] FIG. 60 is a partial, perspective, cross-section view of the
shaft and the disposable loading unit of FIG. 59, depicting the
disposable loading unit partially-inserted into the shaft, and
further depicting a latch in an unlatched position;
[0068] FIG. 61 is a partial, perspective, cross-section view of the
shaft and the disposable loading unit of FIG. 59, depicting the
disposable loading unit fully-inserted into the shaft, and further
depicting the latch in a latched position;
[0069] FIG. 62 is a partial, elevation, cross-section view of the
shaft and the disposable loading unit of FIG. 59, depicting the
disposable loading unit fully-inserted into the shaft, and further
depicting the latch in the latched position;
[0070] FIG. 63 is a schematic of a torque-voltage curve according
to various embodiments of the present disclosure;
[0071] FIG. 64(a) is a schematic of high duty cycle pulses
delivered by a pulse width modulation circuit according to various
embodiments of the present disclosure;
[0072] FIG. 64(b) is a schematic of low duty cycle pulses delivered
by a pulse width modulation circuit according to various
embodiments of the present disclosure;
[0073] FIG. 65(a) is a schematic of a firing element driven by the
high duty cycle pulses of the pulse width modulation circuit of
FIG. 64(a);
[0074] FIG. 65(b) is a schematic of a firing element driven by the
low duty cycle pulses of the pulse width modulation circuit of FIG.
64(b);
[0075] FIGS. 66(a)-66(c) are schematics of pulse width modulation
circuits having a primary set of coils and a secondary set of coils
according to various embodiments of the present disclosure;
[0076] FIG. 67 is a graph depicting speed and torque throughout a
firing stroke according to various embodiments of the present
disclosure;
[0077] FIG. 68 is a graph depicting a speed limiting trial segment
during a firing stroke according to various embodiments of the
present disclosure;
[0078] FIGS. 69 and 70 are schematics of a simplified stepper motor
according to various embodiments of the present disclosure;
[0079] FIGS. 71-73 are schematics of a hybrid stepper motor
according to various embodiments of the present disclosure;
[0080] FIGS. 74(a)-74(c) are schematics of the hybrid stepper motor
of FIGS. 71-73 illustrating the changing polarities;
[0081] FIG. 75 is a perspective view of a display that includes a
touch screen for use with an endoscope according to various
embodiments of the present disclosure;
[0082] FIG. 76 is an elevation view of a first layer of information
for depiction on the display of FIG. 75, wherein the first layer of
information includes video feedback of a disposable loading unit
(DLU) attached to a surgical instrument as viewed by the
endoscope;
[0083] FIG. 77 is an elevation view of a second layer of
information for depiction on the display of FIG. 75, wherein the
second layer of information includes a control panel for accepting
input via the touch screen;
[0084] FIG. 78 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76;
[0085] FIG. 79 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes numerical
data related to the progression of the knife and a visual
representation of the progression of the knife when the knife is
near the beginning of a firing stroke;
[0086] FIG. 80 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes numerical
data related to the progression of the knife and a visual
representation of the progression of the knife when the knife is
near the distal end of the firing stroke;
[0087] FIG. 81 is an elevation view of the second layer of
information FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes a
symbolic representation of the knife overlapping the detected
position of the knife in the DLU depicted in the first layer of
information;
[0088] FIG. 82 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes a
graphical representation of the speed of the distally advancing
knife during a firing stroke;
[0089] FIG. 83 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes a
graphical representation of the clamping force exerted by the DLU
jaws on the tissue along the length of the DLU jaws;
[0090] FIG. 84 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes numerical
data related to the orientation of the DLU, and wherein the DLU
depicted in the first layer of information is in an unarticulated
orientation;
[0091] FIG. 85 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes numerical
data related to the orientation of the DLU and a visual
representation of the orientation of the DLU, and wherein the DLU
depicted in the first layer of information is in an articulated
orientation;
[0092] FIG. 86 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76 illustrating input from a user for adjusting the
articulation of the DLU via the touch screen of FIG. 75;
[0093] FIG. 87 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76 illustrating a schematic for controlling the DLU and
further illustrating input from a user for adjusting the
articulation of the DLU by manipulating the schematic via the touch
screen of FIG. 75;
[0094] FIG. 88 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76 illustrating the DLU in an articulated orientation in the
first layer of information in response to the user input
illustrated in FIGS. 86 and 87;
[0095] FIG. 89 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76 illustrating input from a user for controlling the closure
of the moveable jaw via the touch screen of FIG. 75;
[0096] FIG. 90 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76 illustrating the moveable jaw of the DLU in a clamped
orientation in the first layer of information in response to the
user input depicted in FIG. 89;
[0097] FIG. 91 is an elevation view of a controller interface for
the secondary layer of information of FIG. 77;
[0098] FIG. 92 is an elevation view of the second layer of
information of FIG. 77 overlaying the first layer of information of
FIG. 76, wherein the second layer of information includes the
controller interface of FIG. 91 and a progression bar;
[0099] FIG. 93 is a schematic illustrating a communication system
for a feedback controller and the endoscope, the surgical
instrument, and the display of FIG. 75;
[0100] FIG. 94 is an exploded view of a surgical instrument system
including a handle and an end effector including a plurality of
indicators in accordance with at least one embodiment;
[0101] FIG. 95 is a partial elevational view of a handle of a
surgical instrument system including a plurality of indicators in
accordance with at least one embodiment;
[0102] FIG. 96 is a partial cross-sectional view of a handle of a
surgical instrument system including a trigger lock in accordance
with at least one embodiment illustrated with the trigger lock in
an unlocked condition;
[0103] FIG. 97 is a partial cross-sectional view of the handle of
FIG. 96 illustrating the trigger lock in a locked condition;
[0104] FIG. 98 is a cross-sectional view of the trigger lock of
FIG. 96 illustrating the trigger lock in its unlocked
condition;
[0105] FIG. 99 is a cross-sectional view of the trigger lock of
FIG. 96 illustrating the trigger lock in its locked condition;
[0106] FIG. 99A is a flow chart outlining an operating program of a
controller of a surgical instrument for assessing whether the
surgical instrument has been exposed to a temperature which exceeds
its threshold temperature and determining the manner in which to
notify the user of the surgical instrument that the threshold
temperature has been exceeded;
[0107] FIG. 100 is a cross-sectional view of a handle of a surgical
instrument system including a trigger lock in a locked condition in
accordance with at least one embodiment;
[0108] FIG. 101 is a cross-sectional detail view of the handle of
FIG. 100 illustrating the trigger lock in its locked condition;
[0109] FIG. 102 is another cross-sectional detail view of the
handle of FIG. 100 illustrating the trigger lock in an unlocked
condition;
[0110] FIG. 103 is a perspective view of the trigger lock of FIG.
100 illustrated in its locked condition;
[0111] FIG. 104 is a partial cross-sectional perspective view of a
handle of a surgical instrument including a trigger lock in a
locked condition in accordance with at least one embodiment;
[0112] FIG. 105 is a partial cross-sectional perspective view of
the handle of FIG. 104 illustrated in an unlocked condition;
[0113] FIG. 106 is a partial cross-sectional left side view of the
handle of FIG. 104 illustrated in its locked condition;
[0114] FIG. 107 is a partial cross-sectional right side view of the
handle of FIG. 104 illustrated in its locked condition;
[0115] FIG. 108 is a partial cross-sectional left side view of the
handle of FIG. 104 illustrated in its unlocked condition;
[0116] FIG. 109 is a partial cross-sectional right side view of the
handle of FIG. 104 illustrated in its unlocked condition;
[0117] FIG. 110 is a process flow diagram illustrating the steps
that a controller of a surgical instrument can utilize to process a
signal received from an end effector attached to the surgical
instrument;
[0118] FIG. 110A is a schematic depicting an array of parameters
which can be supplied from an end effector to a surgical
instrument;
[0119] FIG. 111 is a process flow diagram illustrating the steps
for using the end effector and surgical instrument of FIG. 110;
[0120] FIG. 112 is a schematic illustrating an interconnection
between an end effector and a shaft of a surgical instrument in
accordance with at least one embodiment;
[0121] FIG. 113 is a plan view of a printed circuit board of the
interconnection of FIG. 112;
[0122] FIG. 114 is a partial perspective view of an end effector of
a surgical instrument in accordance with at least one
embodiment;
[0123] FIG. 115 is a partial perspective view of the end effector
of FIG. 114 and a shaft of a surgical instrument;
[0124] FIG. 116 is a cross-sectional view of the end effector of
FIG. 114 attached to the shaft of FIG. 115;
[0125] FIG. 117 is a cross-sectional view of an interconnection
between an end effector and a shaft in accordance with at least one
embodiment;
[0126] FIG. 118 is a cross-sectional view of an interconnection
between an end effector and a shaft in accordance with at least one
embodiment;
[0127] FIG. 119 is a cross-sectional view of an interconnection
between an end effector and a shaft in accordance with at least one
embodiment;
[0128] FIG. 120 is a detail view of the interconnection of FIG.
119;
[0129] FIG. 121 is a side view of an end effector comprising an
anvil and an anvil position indicator in accordance with at least
one embodiment illustrating the anvil in an open position;
[0130] FIG. 122 is a side view of the end effector of FIG. 121
illustrating the anvil in a partially-closed position;
[0131] FIG. 123 is another side view of the end effector of FIG.
121 illustrating the anvil in a partially-closed position;
[0132] FIG. 124 is another side view of the end effector of FIG.
121 illustrating the anvil in a partially-closed position;
[0133] FIG. 125 is a detail view of the anvil position indicator of
FIG. 121 depicting the anvil in the position illustrated in FIG.
121;
[0134] FIG. 126 is a detail view of the anvil position indicator of
FIG. 121 depicting the anvil in the position illustrated in FIG.
122;
[0135] FIG. 127 is a detail view of the anvil position indicator of
FIG. 121 depicting the anvil in the position illustrated in FIG.
123;
[0136] FIG. 128 is a detail view of the anvil position indicator of
FIG. 121 depicting the anvil in the position illustrated in FIG.
124;
[0137] FIG. 129 illustrates a cross-sectional side of view of a
surgical instrument according to certain embodiments described
herein;
[0138] FIG. 130 illustrates a power system for powering the
surgical instrument of FIG. 129, wherein the power system is in
communication with a control system of the surgical instrument of
FIG. 129;
[0139] FIG. 131 illustrates a battery pack of the power system of
FIG. 130 connected to a charger base;
[0140] FIG. 132 illustrates a power management circuit of the power
system of FIG. 130;
[0141] FIG. 133 illustrates a schematic block diagram exemplifying
operation parameters of the power system of FIG. 130;
[0142] FIG. 134 illustrates a perspective view of a power source of
a surgical instrument according to various embodiments described
herein;
[0143] FIG. 135 illustrates a perspective view of the power source
of FIG. 134 disassembled according to various embodiments described
herein;
[0144] FIG. 136 illustrates a circuit diagram of a circuit of the
power source of FIG. 134 including an intact breakable portion
according to various embodiments described herein;
[0145] FIG. 137 illustrates the circuit diagram of the circuit of
FIG. 136 with the breakable portion broken according to various
embodiments described herein;
[0146] FIG. 138 illustrates a block diagram of a system for
protecting data stored in a memory from unauthorized access
according to various embodiments described herein;
[0147] FIG. 139 illustrates a perspective view of a power source of
a surgical instrument including a covered data access portal;
[0148] FIG. 140 illustrates the data access portal of FIG. 139 in
an uncovered configuration;
[0149] FIG. 141 illustrates a perspective view of a power source of
a surgical instrument including an internal data access portal;
[0150] FIG. 142 illustrates a block diagram of a system for
protecting data stored in a memory from unauthorized access
according to various embodiments described herein;
[0151] FIG. 143 illustrates a perspective view of a power source of
a surgical instrument according to various embodiments described
herein;
[0152] FIG. 144 illustrates a perspective view of the power source
of FIG. 143 coupled to the surgical instrument;
[0153] FIG. 145 illustrates LEDs of the power source of FIG. 143 in
different configurations according to various embodiments described
herein;
[0154] FIG. 146 illustrates a side view of a surgical instrument
including a housing in accordance with various embodiments
described herein;
[0155] FIG. 147 illustrates a side view of the housing of FIG. 146
with an outer shell removed to expose detachable components secured
to the housing by securing members;
[0156] FIG. 148 illustrates a side view of the housing in FIG. 147
with the detachable components removed from the housing;
[0157] FIG. 149 is a schematic depicting detectable indentations,
notches, or impressions of a barcode defined in a surface of an end
effector;
[0158] FIG. 150 is a schematic of an exemplary bar code usable with
a bar code reader;
[0159] FIG. 151 is a partial side view of a shaft of an end
effector including a bar code in accordance with at least one
embodiment;
[0160] FIG. 152 is a partial elevational view of an end effector of
a surgical instrument including a bar code in accordance with at
least one embodiment;
[0161] FIG. 153 is a partial perspective view of a handle of a
surgical instrument including a bar code reader in accordance with
at least one embodiment;
[0162] FIG. 154 is a cross-sectional view of the bar code reader of
FIG. 153 illustrated with an end effector positioned therein;
[0163] FIG. 155 is an exploded perspective view of an end effector
and a shaft of a surgical instrument in accordance with at least
one embodiment;
[0164] FIG. 156 is an exploded perspective view of an end effector
and a shaft of a surgical instrument in accordance with at least
one embodiment wherein the end effector comprises portions of a
firing member releasably locked together;
[0165] FIG. 157 is a partial perspective view of the firing member
portions of FIG. 156 locked together by a lock member;
[0166] FIG. 158 is a partial perspective view of the firing member
portions and the lock member of FIG. 156 illustrated with a portion
of the firing member removed to illustrate the lock member
releasably locking the firing member portions together;
[0167] FIG. 159 is an exploded view of the firing member of FIG.
156 and a release actuator configured to move the lock member into
an unlocked condition and unlock the firing member portions;
[0168] FIG. 160 is a partial exploded view of an interconnection
between the release actuator of FIG. 159 and a corresponding shaft
release actuator;
[0169] FIG. 161 is a cross-sectional view of the interconnection of
FIG. 160;
[0170] FIG. 162 is an exploded perspective view of an assembly
comprising a motor, a drive shaft, and a slip clutch configured to
selectively transmit rotation between the motor and the drive
shaft;
[0171] FIG. 163 is a cross-sectional view of the assembly of FIG.
162;
[0172] FIG. 164 is a perspective view of a biasing element of the
slip clutch of FIG. 162;
[0173] FIG. 165 is a cross-sectional view of the assembly of FIG.
162 illustrating a clutch element of the slip clutch in a neutral
position;
[0174] FIG. 166 is a cross-sectional view of the assembly of FIG.
162 illustrating the clutch element of FIG. 165 in a forward
position;
[0175] FIG. 167 is a cross-sectional view of the assembly of FIG.
162 illustrating the clutch element of FIG. 165 in a reverse
position;
[0176] FIG. 168 is a perspective view of a motor and a gear
assembly according to various embodiments of the present
disclosure;
[0177] FIG. 169 is a perspective view of a motor, a gear assembly,
and an audio feedback generator according to various embodiments of
the present disclosure;
[0178] FIG. 170 is an elevational view of a pick on a disk of the
gear assembly of FIG. 169, depicting the disk rotating in a
clockwise direction and the pick engaging a clicker of the audio
feedback generator of FIG. 169 according to various embodiments of
the present disclosure;
[0179] FIG. 171 is an elevational view of a pick on a disk of the
gear assembly of FIG. 169, depicting the disk rotating in a
counterclockwise direction and the pick engaging a clicker of the
audio feedback generator of FIG. 169 according to various
embodiments of the present disclosure;
[0180] FIG. 172 is a perspective view of a motor, a gear assembly
having multiple disks, and an audio feedback generator according to
various embodiments of the present disclosure;
[0181] FIG. 173 is a graphical depiction of feedback generated near
the end of a firing stroke by the audio feedback generator of FIG.
172 according to various embodiments of the present disclosure;
[0182] FIGS. 174 and 175 are graphical depictions of feedback
generated near the articulation limit of a loading unit by the
audio feedback generator of FIG. 172 according to various
embodiments of the present disclosure;
[0183] FIG. 176 is a schematic depicting an algorithm for operating
a surgical instrument;
[0184] FIG. 177 is another schematic depicting an algorithm for
operating a surgical instrument;
[0185] FIG. 178 is a schematic depicting an algorithm for operating
a surgical instrument;
[0186] FIG. 179 is a circuit configured to indicate the voltage of
a battery;
[0187] FIG. 180 is a flasher schematic configured to indicate that
a battery is charged;
[0188] FIG. 181 is a schematic of a diagnostic check for use with a
surgical instrument in accordance with at least one embodiment;
[0189] FIG. 182 is a schematic illustrating the discharge of a
battery and a power cutoff once the charge of the battery is below
a minimum charge level;
[0190] FIG. 183 is a table of information that can be maintained
which records the operation and/or performance of a battery;
[0191] FIG. 184 is a schematic of a battery diagnostic circuit;
[0192] FIG. 185 is a perspective view of a sealed motor and gear
assembly for use with a surgical instrument according to various
embodiments of the present disclosure; and
[0193] FIG. 186 is an exploded, elevational, cross-sectional view
of the sealed motor and gear assembly of FIG. 185 according to
various embodiments of the present disclosure.
DETAILED DESCRIPTION
[0194] 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:
[0195] U.S. patent application entitled FIRING MEMBER RETRACTION
DEVICES FOR POWERED SURGICAL INSTRUMENTS, Attorney Docket No.
END7293USNP/130016;
[0196] U.S. patent application entitled SECONDARY BATTERY
ARRANGEMENTS FOR POWERED SURGICAL INSTRUMENTS, Attorney Docket No.
END7294USNP/130017;
[0197] U.S. patent application entitled ERROR DETECTION
ARRANGEMENTS FOR SURGICAL INSTRUMENT ASSEMBLIES, Attorney Docket
No. END7295USNP/130018;
[0198] U.S. patent application entitled ATTACHMENT PORTIONS FOR
SURGICAL INSTRUMENT ASSEMBLIES, Attorney Docket No.
END7296USNP/130019;
[0199] U.S. patent application entitled TAMPER PROOF CIRCUIT FOR
SURGICAL INSTRUMENT BATTERY PACK, Attorney Docket No.
END7297USNP/130020;
[0200] U.S. patent application entitled CLOSURE INDICATOR SYSTEMS
FOR SURGICAL INSTRUMENTS, Attorney Docket No.
END7298USNP/130021;
[0201] U.S. patent application entitled SHROUD RETENTION
ARRANGEMENT FOR STERILIZABLE SURGICAL INSTRUMENTS, Attorney Docket
No. END7300USNP/130023;
[0202] U.S. patent application entitled CONDUCTOR ARRANGEMENTS FOR
ELECTRICALLY POWERED SURGICAL INSTRUMENTS WITH ROTATABLE END
EFFECTORS, Attorney Docket No. END7301USNP/130024;
[0203] U.S. patent application entitled END EFFECTOR DETECTION
SYSTEMS FOR SURGICAL INSTRUMENTS, Attorney Docket No.
END7302USNP/130025;
[0204] U.S. patent application entitled FIRING TRIGGER LOCKOUT
ARRANGEMENTS FOR SURGICAL INSTRUMENTS, Attorney Docket No.
END7303USNP/130026;
[0205] U.S. patent application entitled INTERACTIVE DISPLAYS,
Attorney Docket No. END7304USNP/130027; and
[0206] U.S. patent application entitled MOTOR-POWERED ARTICULATABLE
SURGICAL INSTRUMENTS, Attorney Docket No. END7305USNP/130028.
[0207] 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.
[0208] The terms "comprise" (and any form of comprise, such as
"comprises" and "comprising"), "have" (and any form of have, such
as "has" and "having"), "include" (and any form of include, such as
"includes" and "including") and "contain" (and any form of contain,
such as "contains" and "containing") are open-ended linking verbs.
As a result, a surgical system, device, or apparatus that
"comprises," "has," "includes" or "contains" one or more elements
possesses those one or more elements, but is not limited to
possessing only those one or more elements. Likewise, an element of
a system, device, or apparatus that "comprises," "has," "includes"
or "contains" one or more features possesses those one or more
features, but is not limited to possessing only those one or more
features.
[0209] 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.
[0210] 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.
[0211] FIG. 1 illustrates a powered surgical instrument 10 that, in
many ways, may be similar to those surgical instruments (including
various features, components and subcomponents thereof) disclosed
in, for example, Zemlok '763 and/or Zemlok '344, which have each
been incorporated by reference herein in their respective
entireties. The surgical instrument 10 depicted in FIG. 1 includes
a housing 12 that has a handle portion 14 for facilitating manual
manipulation and operation of the instrument. Thus, the term
"housing" as used herein may encompass a handheld or otherwise
hand-manipulatable arrangement. However, the term "housing" may
also encompass portions of an automated surgical instrument system
such as a robotically-controlled system that is not intended to be
handheld but is otherwise manipulated and actuatable by various
components, portions, and/or actuators of the system.
[0212] An elongated shaft assembly 16 in the form of an endoscopic
portion protrudes from the housing 12 and is configured for
operable attachment to a surgical end effector that is constructed
to perform at least one surgical procedure in response to
applications of firing motions thereto. Such surgical end effectors
may comprise, for example, endocutters, graspers or other devices
that may include a pair of jaws wherein one jaw is selectively
movable relative to the other jaw or in some configurations, both
jaws are movable relative to each other. By way of further example,
the surgical end effector may comprise a device configured to cut
and staple tissue such as a "loading unit" 20 as shown in FIGS. 2
and 3. Surgical end effectors, such as loading unit 20, for
example, can be releasably attached to the elongated shaft assembly
16 of the powered surgical instrument 10, as described in greater
detail herein.
[0213] FIGS. 2 and 3 illustrate one exemplary form of a loading
unit 20 that may be employed with the surgical instrument 10. Such
loading unit 20 may be similar to those loading units disclosed in
the aforementioned U.S. patent application Publications, which have
been each herein incorporated by reference in their entireties as
well as those loading units disclosed in, for example, U.S. Patent
Application Publication No. US 2012-0298719-A1, entitled SURGICAL
STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS,
the disclosure of which is hereby incorporated by reference in its
entirety herein.
[0214] As can be seen in FIG. 2, the loading unit 20 includes an
anvil assembly 22 that is supported for pivotal travel relative to
a carrier 24 that operably supports a staple cartridge 26 therein.
A mounting assembly 28 is pivotally coupled to the cartridge
carrier 24 to form an articulation joint 27 that enables the
carrier 24 to pivot about an articulation axis "AA-AA" that is
transverse to a longitudinal tool axis "LA-LA". Referring to FIG.
3, mounting assembly 28 may include, for example, upper and lower
mounting portions 30 and 32. Each mounting portion 30, 32 may
include a threaded bore 34 on each side thereof that is dimensioned
to receive threaded bolts (not shown) for securing the proximal end
of carrier 24 thereto. A pair of centrally located pivot members 36
may extend between upper and lower mounting portions via a pair of
coupling members 38 which engage a distal end of a housing portion
40. Coupling members 38 may each include an interlocking proximal
portion 39 that is configured to be received in grooves 42 that are
formed in the proximal end of housing portion 40 to retain mounting
assembly 30 and housing portion 40 in a longitudinally fixed
position.
[0215] As can be further seen in FIG. 3, housing portion 40 of
loading unit 20 may include an upper housing half 44 and a lower
housing half 46 that are each configured to be received within an
outer casing 50. The proximal end of housing half 44 may include
engagement nubs 48 for releasably engaging a distal end of an
elongated shaft assembly 16. The nubs 48 may form a "bayonet-type"
coupling with the distal end of the elongated shaft assembly 16,
for example. Various coupling arrangements are described in greater
detail herein. Housing halves 44, 46 may define a channel 47 for
slidably receiving an axially-movable drive beam 60. A second
articulation link 70 may be dimensioned to be slidably positioned
within a slot 72 formed between housing halves 44, 46. A pair of
"blowout" plates 74 may be positioned adjacent the distal end of
housing portion 40 adjacent the distal end of axial drive beam 60
to prevent outward bulging of the drive beam 60 during articulation
of carrier 24.
[0216] The drive beam 60 may include a distal working head 62 and a
proximal engagement section 64. Drive beam 60 may be constructed
from a single sheet of material or, preferably, from multiple
stacked sheets. Engagement section 64 may include a pair of
engagement fingers which are dimensioned and configured to
mountingly engage a pair of corresponding retention slots formed in
drive member 66. Drive member 66 may include a proximal porthole 67
that is configured to receive a distal end of a firing rod when the
proximal end of loading unit 20 is engaged with elongated shaft
assembly of the surgical instrument 10. The distal working head 62
may have a tissue cutting portion 63 formed thereon. The distal
working head 62 may further include a pair of pins 65 that are
configured to engage the anvil assembly 22 to pivot it to a closed
position to clamp tissue between the anvil 22 and the staple
cartridge 26 as the distal working head 62 is distally driven
through the staple cartridge 26. A tissue cutting portion 63 on the
distal working head 62 serves to cut through the clamped tissue as
the surgical staples (not shown) that are supported in the staple
cartridge 26 are driven into forming contact with the anvil 22 in a
known manner. For example, the distal working head 62 is configured
to axially engage and advance a sled (not shown) that is movably
supported in the staple cartridge 26. As the sled is driven in the
distal direction by the drive member 66, the sled contacts pushers
(not shown) that are associated with the staples and causes the
pushers to drive the staples out of the cartridge 26 into forming
engagement with anvil 22 on the loading unit 20.
[0217] As can be seen in FIG. 1, the surgical instrument 10
includes a motor 100 that is configured to generate rotary
actuation motions that may be employed, for example, to apply
firing motions to the loading unit 20 as will be discussed in
further detail below. In at least one form, for example, the motor
100 is configured to apply rotary actuation motions to a firing
member assembly, generally designated as 82. In one arrangement,
for example, the firing member assembly 82 includes a drive tube
102 that is rotatably supported within the housing 12 and has an
internal thread (not shown) formed therein. A proximal threaded
portion of a firing rod 104 is supported in threaded engagement
with the drive tube 102 such that rotation of the drive tube 102
results in the axial movement of the firing rod 104. The firing rod
104 may threadably interface with the interior of the drive beam 60
in the loading unit 20. As discussed in further detail in the
aforementioned incorporated Zemlok '763 and Zemlok '344, rotation
of drive tube 102 in a first direction (e.g., counter-clockwise)
causes the firing rod 104 to advance the drive member 60 in the
distal direction. Initial advancement of the drive member 60 in the
distal direction within the loading unit 20 causes the anvil 22 to
pivot toward the staple cartridge 26. The anvil 22 is actuated by
pins 65 on the drive member 60 which serve to cam the anvil 22 to a
closed position as the drive member 60 is initially driven in the
distal direction "DD". Additional distal translation of firing rod
104 and ultimately of the drive member 60 through the loading unit
20 causes the staples to be driven into forming contact with the
staple forming undersurface on the anvil 22.
[0218] As can be further seen in FIG. 1, the surgical instrument 10
may include an articulation system generally designated as 109.
However, surgical instrument 10 may include various other
articulation system arrangements disclosed in detail herein. In at
least one form, the articulation system 109 may include an
articulation mechanism 110 that includes an articulation motor 112
and a manual articulation knob 114. The articulation motor 112 may
be actuated by a powered articulation switch 116 or by pivoting the
manual articulation knob 114. Actuation of the articulation motor
112 serves to rotate an articulation gear 118 of the articulation
mechanism 110. Actuation of articulation mechanism 110 may cause
the end effector (e.g., the cartridge/anvil portion of the loading
unit 20) to move from its first position, wherein its axis is
substantially aligned with longitudinal tool axis "LA-LA" of the
elongated shaft assembly 16 to a position in which the axis of the
end effector is disposed at an angle relative to the longitudinal
tool axis "LA-LA" of the elongated shaft assembly about, for
example, articulation axis "AA-AA". Further discussion regarding
various aspects of the articulation mechanism 110 may be found in
Zemlok '763 which was previously incorporated by reference herein
in its entirety. In addition, U.S. Pat. No. 7,431,188 entitled
SURGICAL STAPLING APPARATUS WITH POWERED ARTICULATION, the entire
disclosure of which is hereby incorporated by reference herein,
discloses motor-powered articulatable end effectors which may be
employed in connection with surgical instrument 10.
[0219] In various embodiments, the surgical instrument can include
at least one motor, which can apply firing motions to the loading
unit 20 and/or articulation motions to the articulation system 109,
as described elsewhere in greater detail. The motor 100 may, for
example, be powered by a power source 200 of the type described in
further detail in Zemlok '763. For example, the power source 200
may comprise a rechargeable battery (e.g., lead-based,
nickel-based, lithium-ion based, etc.). It is also envisioned that
the power source 200 may include at least one disposable battery.
The disposable battery may, for example, be between about 9 volts
and about 30 volts. However, other power sources may be employed.
FIG. 1 illustrates one example wherein the power source 200
includes a plurality of battery cells 202. The number of battery
cells 202 employed may depend upon the current load requirements of
the instrument 10.
[0220] In certain embodiments, the surgical instrument 10 can
include a secondary power source for powering the at least one
motor of the surgical instrument 10. For example, referring now to
FIG. 129, the surgical instrument 10 may include a power system
2000 which can be configured to provide energy for operation of the
surgical instrument 10. The power system 2000, as illustrated in
FIG. 129, can be placed, for example, in the handle portion 14 of
the housing 12 and may include a primary power source 2002 and a
secondary or backup power source 2004. The primary power source
2002 can be configured to provide energy for operation of the
surgical instrument 10 during normal operation and the secondary
power source 2004 can be configured to provide energy for operation
of the surgical instrument 10, at least in a limited capacity, when
the primary power source 2002 is not available to provide energy
for the operation of the surgical instrument 10, for example, when
the primary power source 2002 is depleted, and/or when disconnected
from the surgical instrument 10. For example, the secondary power
source 2002 can be configured to provide energy to restore the
surgical instrument 10 to a default status in the event the primary
power source 2002 is depleted and/or disconnected from the surgical
instrument 10 during a surgical procedure.
[0221] Referring to FIG. 1, as described elsewhere in greater
detail, a power source such as, for example, the power source 200
can supply power for operation of the surgical instrument 10. For
example, the power source 200 can supply power for a motor such as,
for example, motor 100 to cause rotation of the drive tube 102 in a
first direction and ultimately the axial advancement of the firing
rod 104 which drives the drive beam 60 distally through the loading
unit 20. Alternatively, the power source 200 can supply power for
the motor 100 to cause rotation of the drive tube 102 in a second
direction opposite the first direction and ultimately the axial
retraction of the firing rod 104 which can move the drive beam 60
proximally to its starting and/or default position. Similarly, the
primary power source 2002 can be configured to supply power for the
motor 100 to advance and/or retract the firing rod 104 during
normal operation of the surgical instrument 10. In addition, the
secondary power source 2004 can be configured to supply power
needed to retract the firing rod 104 to the default position in the
event the primary power source 2002 becomes unavailable to provide
the needed power such as, for example, when the primary power
source 2002 is depleted and/or disconnected from the surgical
instrument 10.
[0222] Further to the above, as described elsewhere in greater
detail, the surgical instrument 10 can be configured to record and
store a variety of information about the operation of the surgical
instrument 10 during a surgical procedure such as, for example, an
articulation angle of end effector 20 (See FIG. 2), an actuation
status of the end effector 20, sensor readings, number of firings,
tissue thickness, and/or position of the firing rod 104. In certain
examples, such information can be recorded and stored in a volatile
or temporary memory such as, for example, a random access memory
(RAM) unit which may require power to maintain the stored
information. During normal operation of the surgical instrument 10,
the primary power source 2002, similar to other power sources
described elsewhere in greater detail, may supply the power needed
to maintain the stored information within the volatile or temporary
memory units of the surgical instrument 10. In addition, the
secondary power source 2004 can supply the power needed to
temporarily maintain the stored information in the event the
primary power source 2002 becomes unavailable to supply the needed
power such as, for example, when the primary power source 2002 is
depleted and/or disconnected from the surgical instrument 10.
[0223] In certain aspects, the surgical instrument 10 may include a
control system 2005 of the type and construction disclosed in
Zemlok '763, which has been herein incorporated by reference in its
entirety. Further details regarding the construction and operation
of such control system 2005 may be obtained from that publication.
For example, the control system 2005 may be configured to generate
or provide information, such as a warning or instrument state, to a
user via a user interface, such as a visual or audio display.
Signals or inputs generated by the control system 2005 may be, for
example, in response to other signals or inputs provided by the
user, instrument components, or may be a function of one or more
measurements associated with the instrument 10. During normal
operation of the surgical instrument 10, as described elsewhere in
greater detail, a power source such as, for example, the primary
power source 2002 (See FIG. 129) can supply power needed to permit
the control system 2005 to perform its functions including
interactions with a user through the user interface. In addition,
the secondary power source 2004 can supply, in at least a limited
capacity, the power needed to temporarily interact with a user
through the user interface in the event the primary power source
2002 becomes unavailable to supply the needed power such as, for
example, when the primary power source 2002 is depleted and/or
disconnected from the surgical instrument 10.
[0224] Referring now to FIG. 130, the power system 2000 may
comprise power management circuit 2006 which may be connected to
the primary power source 2002 and the secondary power source 2004.
The power management circuit 2006 may include or may be selectively
associated with a semiconductor, computer chip, or memory. The
power management circuit 2006 may be configured to send or receive
analog or digital inputs or signals to or from various components
of the surgical instrument 10 including but not limited to the
control system 2005, the primary power source 2002, and/or the
secondary power source 2004. In various aspects, the power
management circuit 2006 may use software that may employ one or
more algorithms to further formulate input signals to control and
monitor various components of the surgical instrument 10 including
the primary power source 2002 and/or the secondary power source
2004. Such formulated input signals may be a function of criteria
measured and/or calculated by the power management circuit 2006 or,
in some instances, provided to the power management circuit 2006 by
another instrument component, a user, or a separate system in
operative communication with the power management circuit 2006.
[0225] Referring again to FIG. 129, the primary power source 2002
may comprise one or more battery cells depending on the current
load needs of the instrument 10. In various aspects, as illustrated
in FIG. 129, the primary power source 2002 may include a battery
pack 2008 which may include a plurality of battery cells 2010 which
may be connected in series with each other, for example. The
battery pack 2008 can be replaceable. In other words, the battery
pack 2008 can be disconnected and removed from the surgical
instrument 10 and replaced with another similar battery pack. In
certain aspects, the primary power source 2002 may comprise a
rechargeable battery (e.g., lead-based, nickel-based, lithium-ion
based, etc.). The battery cells 2008 may be, for example, 3-volt
lithium battery cells, such as CR 123A battery cells, although, for
example, in other embodiments, different types of battery cells
could be used such as battery cells with different voltage levels
and/or different chemistries, for example. A user may disconnect
and remove a depleted or used battery pack 2008 from the surgical
instrument 10 and connect a charged battery pack 2008 to power the
surgical instrument 10. The depleted battery pack 2008 can then be
charged and reused. It is also envisioned that the primary power
source 2002 may include at least one disposable battery. In various
aspects, the disposable battery may be between about 9 volts and
about 30 volts, for example. A user may disconnect and remove a
depleted disposable battery pack 2008 and connect a new disposable
battery pack 2008 to power the surgical instrument 10.
[0226] As described above, the battery pack 2008 may include
rechargeable battery cells and can be removably placed within the
handle portion 14 of the housing 12, for example. In such
circumstances, the battery pack 2008 can be charged using a charger
base. For example, as illustrated in FIG. 131, charger base 2012
can be connected to battery pack 2008 by removing the battery pack
2008 from its location in the handle portion 14 and connecting it
to the charger base 2012. As shown in FIG. 131, the charger base
2012 may comprise a power source 2014 for charging the battery pack
2008. The power source 2014 of the charger base 2012 may be, for
example, a battery (or a number of series-connected batteries), or
an AC/DC converter that converters AC power, such as from
electrical power mains, to DC, or any other suitable power source
for charging the battery pack 2008. The charger base 2012 may also
comprise indicator devices, such as LEDs, a LCD display, etc., to
show the charge status of the battery pack 2008.
[0227] In addition, as shown in FIG. 131, the charger base 2012 may
comprise one or more processors 2016, one or more memory units
2018, and i/o interfaces 2020, 2022, for example. Through the first
i/o interface 2020, the charger base 2012 may communicate with the
power pack 2008 (via a power pack's i/o interface) to allow, for
example, data stored in a memory of the power pack 2008 to be
downloaded to the memory 2020 of the charger base 2012. In various
circumstances, the downloaded data can then be downloaded to
another computer device via the second i/o interface 2022 for
evaluation and analysis, such as by the hospital system in which
the operation involving the instrument 10 is performed, by the
office of the surgeon, by the distributor of the instrument, by the
manufacturer of the instrument, etc.
[0228] The charger base 2012 may also comprise a charge meter 2024
for measuring the charge across the battery cells of the battery
pack 2008. The charge meter 2024 may be in communication with the
processor 2016, so that the processor 2016 can determine in
real-time the suitability of the battery pack 2008 for use to
ensure that the battery would perform as expected.
[0229] Referring again to FIG. 129, the secondary power source 2004
may comprise one or more battery cells 2026 which can be disposed,
for example, within the handle portion 14. The battery cell 2026
can be rechargeable (e.g., lead-based, nickel-based, lithium-ion
based, etc.). For example, the battery cell 2026 may be a 3-volt
lithium battery cell, such as CR 123A battery cell. In addition,
the battery cell 2026 can be configured to be recharged without
being removed from the instrument 10. For example, the primary
power source 2002 can be utilized to charge the battery cell 2026
when the primary power source 2002 is connected to the instrument
10.
[0230] Referring to FIG. 132, an exemplary embodiment of the power
management circuit 2006 is illustrated. Among other things, the
power management circuit 2006 can be configured to monitor
electrical parameters associated with the operation of the primary
power source 2002 and/or the secondary power source 2004. For
example, the power management circuit 2006 can be configured to
monitor power levels in the primary power source 2002 and/or the
secondary power source 2004. The power management circuit 2006, as
shown in FIG. 132, may comprise a charge meter 2028 which may be
configured to measure the charge across the primary power source
2002 and/or the secondary power source 2004. The power management
circuit 2006 also may comprise a non-volatile memory 2030, such as
flash or ROM memory, for example, and one or more processors 2032.
The processor 2032 may be connected to and may control the memory
2030. In addition, the processor 2032 may be connected to the
charge meter 2028 to read the readings of and otherwise control the
charge meter 2028. Additionally, the processor 2032 may control
output devices of the power management circuit 2006 such as, for
example, LEDs.
[0231] The reader will appreciate that charge meters 2024 and/or
2028 may be configured to measure voltage, charge, resistance
and/or current. In certain examples, the charge meters 2024 and/or
2028 may comprise a battery capacity measurement circuit which may
be configured to measure state of voltage under a predetermined
load.
[0232] Further to the above, the processor 2032 can store
information about the primary power source 2002 and/or the
secondary power source 2004 in the memory 2030. The information may
include among other things total charge available, number of uses,
and/or performance. Additionally, the information stored in the
memory 2030 may comprise ID values for the primary power source
2002 that the power management circuit 2006 may read and store.
Such IDs may be, for example, RFIDs that the power management
circuit 2006 read via a RFID transponder 2034. The RFID transponder
2034 may read RFIDs from the power sources that include RFID tags.
The ID values may be read, stored in the memory 2030, and compared
by the processor 2032 to a list of acceptable ID values stored in
the memory 2030 or another store associated with the power
management circuit 2006, to determine, for example, if the
removable/replaceable primary power source 2002 associated with the
read ID value is authentic and/or proper. In such circumstances, if
the processor 2032 determines that the removable/replaceable
component associated with the read ID value is not authentic, the
power management circuit 2006 may be configured to prevent use of
the instrument 10, such as by opening a switch (not shown) that
would prevent power from being delivered to the instrument 10.
Various parameters that the processor 2032 may evaluate to
determine whether the component is authentic and/or proper include
date code, component model/type, manufacturer, regional
information, and/or previous error codes, for example.
[0233] Further to the above, the power management circuit 2006 may
also comprise an i/o interface 2036 for communicating with another
device, for example a computer, to permit the data stored in the
memory 2030 to be downloaded to the other device for evaluation and
analysis, such as by the hospital system in which the operation
involving the instrument 10 is performed, by the office of the
surgeon, by the distributor of the instrument, and/or by the
manufacturer of the instrument, for example. The i/o interface 2036
may be, for example, a wired or wireless interface.
[0234] Referring to the block diagram illustrated in FIG. 133, the
power management circuit 2006 may selectively transmit power to the
surgical instrument 10 from the primary power source 2002 and the
secondary power source 2004. For example, the processor 2032 may be
programmed to permit power to be transmitted to the instrument 10
from the primary power source 2002 when the primary power source
2002 is available to power the instrument 10 and from the secondary
power source 2004 when the primary power source 2002 is not
available to power the instrument 10.
[0235] During normal operation of the instrument 10, the processor
2032 upon detection and authentication of the primary battery
source 2002, as described above, may permit the primary power
source 2002 to power the instrument 10. The primary power source
2002 may continue to power the instrument 10 until the primary
power source 2002 reaches or falls bellow a predetermined minimum
charge level such as, for example, when the primary power source
2002 is disconnected and/or depleted. The power management circuit
2006 could be employed to determine when the primary power source
2002 reaches or falls bellow the predetermined minimum charge
level. For example, the processor 2032 can be configured to employ
the charge meter 2028 or another similar charge meter to monitor
the charge level of the primary power source 2002 and detect when
the charge level reaches or falls below a predetermined minimum
level that can be stored in the memory 2030 of the power management
circuit 2006. At such point, the processor 2032 may alert the user
to replace the primary power source 2002. The power management
circuit 2006 may include an indicator, such as one or more LEDs, an
LCD display, for example, that is activated to alert a user of the
instrument 10 replace the primary power source 2002. Furthermore,
the processor 2032 may be configured to switch the powering of the
instrument 10 from the primary power source 2002 to the secondary
power source 2004 upon detecting that the charge level of the
primary power source 2002 has reached or fallen below the
predetermined minimum level. The reader will appreciate that
additional indicators can be utilized to provide a user with
additional feedback. For example, an indicator can be utilized to
alert the user that instrument 10 is switching from the primary
power source 2002 to the secondary power source 2004, and vise
versa.
[0236] Further to the above, the processor 2032 may be programmed
to permit the primary power source 2002 to charge the secondary
power source 2004 when the primary power source 2002 is connected
to the surgical instrument 10. In certain examples, the secondary
power source 2004 may remain idle once fully charged by the primary
power source 2002 to a predetermined maximum power level for as
long as the primary power source 2002 remains available to power
the instrument 10. In addition, the power management circuit 2006
could be employed to determine when the secondary power source 2004
is sufficiently charged. For example, the processor 2032 can be
configured to employ the charge meter 2028 to monitor the charge
level of the secondary power source 2004 until the charge level
reaches a predetermined maximum level that can be stored in the
memory 2030 of the power management circuit 2006 at which point the
processor 2032 may stop the primary power source 2002 from charging
the secondary power source 2004. The power management circuit 2006
may include an indicator, such as one or more LEDs, an LCD display,
etc., that can be activated to alert a user of the instrument 10
when the secondary power source 2004 is sufficiently charged.
[0237] Referring again to FIG. 129, the primary power source 2002
can be housed within a chamber 2038 of the handle portion 14 of the
instrument 10. To replace the primary power source 2002, an outer
shell of the handle portion 14 can be removed to expose the chamber
2038. In certain examples, a trigger or a switch can be associated
with the outer shell of the handle portion 14 such that attempting
to remove the outer shell of the handle portion 14 may be
understood by the processor 2032 as a triggering event to switch
from the primary power source 2002 to the secondary power source
2004.
[0238] Upon replacing the primary power source 2002 of the surgical
instrument 10 with a new primary power source 2002, the power
management circuit 2006 may check the authenticity of new primary
power source 2002, as described above, and upon confirming such
authenticity, the power management circuit 2006 may permit the new
primary power source 2002 to transmit power to the instrument 10.
In addition, the primary power source 2002 may charge the secondary
power source 2004, as described above.
[0239] Surgical end effectors, such as loading unit 20 (FIGS. 2 and
3), for example, can be operably coupled to the elongated shaft
assembly 16 of the powered surgical instrument 10 (FIG. 1). For
example, referring now to FIGS. 38-58, a surgical end effector,
such as disposable loading unit (DLU) 5502, for example, can be
releasably attached to a surgical instrument, such as powered
surgical instrument 10 (FIG. 1), for example. In various
embodiments, the surgical instrument can include a shaft 5520,
which can engage the DLU 5502, for example. In various embodiments,
a collar, such as rotatable collar 5580, for example, can
releasably lock the DLU 5502 relative to the shaft 5520.
Furthermore, in various embodiments, rotation of the collar 5580
can facilitate attachment and/or alignment of a firing assembly
and/or an articulation assembly, as described herein.
[0240] In various embodiments, the DLU 5502 can include a distal
attachment portion 5504 and the shaft 5520 can include an outer
tube 5554 and a proximal attachment portion 5522. The distal
attachment portion 5504 of the DLU 5502 can receive the proximal
attachment portion 5522 of the shaft 5520 when the DLU 5502 is
secured to the shaft 5520 (FIG. 39). Furthermore, the rotatable
collar 5580 can be positioned around the proximal attachment
portion 5522 of the shaft 5520, such that the distal attachment
portion 5504 of the DLU 5502 can also be positioned within the
rotatable collar 5580. The rotatable collar 5580 can be secured to
the shaft 5502 and/or the proximal attachment portion 5504, and, in
certain embodiments, can be rotatably fixed to the proximal
attachment portion 5504 of the shaft 5502, for example. In certain
embodiments, a proximal attachment portion of the shaft 5520 can
receive a distal attachment portion of the DLU 5502 when the DLU
5502 is secured to the shaft 5520. Furthermore, in certain
embodiments, a collar 5580 can be rotatably fixed to the DLU
5502.
[0241] Referring still to FIGS. 38-58, as the DLU 5502 moves
between a non-attached position and an attached position relative
to the shaft 5520 of the surgical instrument, the DLU 5502 can
translate along a longitudinal axis defined by the shaft 5520. The
distal attachment portion 5504 of the DLU 5502 can be inserted into
the proximal attachment portion 5522 of the shaft 5520 as the DLU
5502 moves from the non-attached position to the attached position.
For example, the DLU 5502 can translate in direction A (FIG. 39)
when the DLU 5502 is moved between the non-attached position and
the attached position. In certain embodiments, a groove-and-slot
engagement between the distal attachment portion 5504 and the
proximal attachment portion 5522 can guide the DLU 5502 along the
longitudinal axis defined by the shaft 5520. Referring primarily to
FIG. 42, the distal attachment portion 5504 can include a guide
rail 5514. Furthermore, referring primarily to FIG. 44, the
proximal attachment portion 5522 can include a guide slot 5534. The
guide slot 5534 can be dimensioned and structured to receive and
guide the guide rail 5514 as the proximal attachment portion 5504
of the DLU 5502 is inserted into the distal attachment portion 5522
of the shaft 5520. For example, the guide slot 5534 can comprise a
longitudinal slot, and the guide rail 5514 can comprise a
longitudinal ridge, for example. In certain embodiments, the guide
slot 5534 and guide rail 5514 can prevent twisting and/or rotating
of the DLU 5502 relative to the longitudinal axis defined by the
shaft 5520.
[0242] Referring primarily to FIG. 38, the distal attachment
portion 5504 can include a first alignment indicia 5510, such as a
first arrow, for example, and the shaft 5520 and/or the collar 5580
can include a second alignment indicia 5590, such as a second
arrow, for example. Alignment of the first and second alignment
indicia 5510, 5590 can align the guide rail 5514 and the guide slot
5534, which can facilitate attachment of the distal attachment
portion 5504 to the proximal attachment portion 5522. As described
herein, translation of the DLU 5502 along a longitudinal path
toward the shaft 5520 can releasably lock the DLU 5502 relative to
the shaft 5520. In such embodiments, rotation of the DLU 5502
relative to the shaft 5520 may not be required to attach the DLU
5502 relative to the shaft 5520. In fact, rotation the DLU 5502
relative to the shaft 5520 can be restrained and/or prevented by a
groove-and-slot engagement between the proximal attachment portion
5522 and the distal attachment portion 5504, as described herein.
In various embodiments, the collar 5580 can rotate relative to the
DLU 5502 and/or the shaft 5520 to releasably lock the DLU 5502 to
the shaft 5520. For example, as described herein, the collar 5580
can rotate from an initial orientation (FIG. 53) toward a secondary
orientation (FIG. 54) and then return toward the initial
orientation (FIG. 57) to lock the DLU 5502 to the shaft 5520.
[0243] Referring primarily to FIGS. 42 and 43, the proximal portion
5504 of the DLU 5502 can include a rotation key or rib 5506. As the
DLU 5502 is moved in direction A (FIG. 39) between a non-attached
position (FIG. 38) and an attached position (FIG. 39), the rotation
key 5506 can affect rotation of the collar 5580. For example, the
rotation key 5506 can rotate and/or bias the collar 5580 in
direction B (FIG. 39) from the initial orientation to the secondary
orientation. The distal attachment portion 5504 can be inserted
into the proximal attachment portion 5522 when the collar 5580 is
biased into the secondary orientation. Furthermore, when the distal
attachment portion 5504 is fully inserted into the proximal
attachment portion 5522, the rotation key 5506 can permit the
collar 5580 to rotate in direction C (FIG. 39) from the secondary
orientation toward the initial orientation. Direction C can be
opposite to direction B, for example. As described herein, when the
collar 5580 returns to the initial orientation, the collar 5580 can
lock the distal attachment portion 5504 relative to the proximal
attachment portion 5522. Referring still to FIGS. 42 and 43, the
rotation key 5506 can include a rotation ramp 5508 at the proximal
end thereof. The rotation ramp 5508 can engage an element of the
shaft 5520 to effect rotation of the rotation collar 5580, for
example.
[0244] In various embodiments, the rotation ramp 5508 can affect
rotation of a firing shaft 5540 positioned within the shaft 5520.
For example, referring primarily to FIGS. 47-50, the firing shaft
5540 can include a firing shaft rotator 5544 which can extend
radially outward from the firing shaft 5540. The rotation ramp 5508
of the rotation key 5506 can engage the firing shaft rotator 5544
when the DLU 5502 is inserted into the shaft 5520. In various
embodiments, the rotation ramp 5508 can rotate the firing shaft
rotator 5544, which can rotate the firing shaft 5540. For example,
the firing shaft 5540 and the firing shaft rotator 5544 can rotate
in direction B (FIG. 54) between a first orientation (FIG. 53) and
a second orientation (FIG. 54). Referring still to FIGS. 47-50, the
firing shaft 5540 can be engaged with the rotatable collar 5580.
For example, the rotatable collar 5580 can include a rotator groove
5584, which can be structured and dimensioned to receive and/or
hold the firing shaft rotator 5544. The firing shaft rotator 5544
can be held by the rotator groove 5584, such that the rotation of
the firing shaft rotator 5544 rotates the rotatable collar 5580. In
such embodiments, insertion of the DLU 5502 into the shaft 5520,
can affect rotation of the rotatable collar 5580 in direction B
(FIG. 54) via rotation of the firing shaft rotator 5544 in
direction B, for example.
[0245] Referring primarily to FIGS. 44 and 45, the proximal
attachment portion 5522 can include a rotation key slot 5524, which
can receive the rotation key 5506 when the distal attachment
portion 5504 is inserted into the proximal attachment portion 5522.
In various embodiments, the rotation key slot 5524 can include a
clearance notch 5526 for receiving the firing shaft rotator 5544.
For example, the rotation ramp 5508 at the proximal end of the
rotation key 5506 can rotate the firing shaft rotator 5544 to the
second orientation and into the clearance notch 5526 (FIG. 54). The
rotation key 5506 can continue to move along the rotation key slot
5524 as the DLU 5502 is inserted into the shaft 5520. Furthermore,
when the distal end 5509 of the rotation key 5506 moves past the
firing shaft rotator 5544, the firing shaft rotator 5544 can rotate
back toward the first orientation (FIG. 58), which can
corresponding rotate the rotatable collar 5580 back toward the
initial orientation thereof.
[0246] In various embodiments, the rotatable collar 5580 can be
biased into the initial orientation relative to the shaft 5520
and/or the proximal attachment portion 5522. For example, a spring
5592 can bias the lock collar 5580 into the initial orientation.
The spring 5592 can include a proximal end 5594 that can be secured
relative to the shaft 5520, and a distal end 5596 that can be
secured relative to the collar 5580. For example, the proximal end
5594 of the spring 5592 can be retained in a proximal spring slot
5538 (FIG. 51) of the shaft 5520, and the distal end 5596 of the
spring 5592 can be retained in a distal spring slot 5588 (FIG. 46)
of the rotatable collar 5580, for example. In such embodiments,
rotation of the collar 5580 can displace the distal end 5596 of the
spring 5592 relative to the proximal end 5594 of the spring 5592,
which can generate a torsional force. Accordingly, the collar 5580
can resist rotation from the initial orientation to the secondary
orientation, and, when the collar is rotated to the secondary
orientation, the spring 5592 can bias the collar 5580 back toward
the initial orientation. Because the firing shaft rotator 5544 is
engaged with the collar 5580, the spring 5592 can also bias the
firing shaft 5540 toward the first orientation thereof.
[0247] In various embodiments, the rotatable collar 5580 can
include a locking detent 5582 that releasably locks the DLU 5502 to
the shaft 5520. Referring primarily to FIG. 46, the locking detent
5582 can extend radially inward from the inner perimeter of the
rotatable collar 5580. In various embodiments, the locking detent
5582 can extend into a detent slot 5536 (FIG. 44) in the proximal
attachment portion 5522. Referring primarily to FIG. 44, the detent
slot 5536 can form a notch in the guide slot 5534. In various
embodiments, the detent slot 5536 can extend from the guide slot
5534, and can be perpendicular or substantially perpendicular to
the guide slot 5534, for example. Further, the locking detent 5582
can move along the detent slot 5536 when the rotatable collar 5580
rotates between the initial orientation and the secondary
orientation relative to the shaft 5520.
[0248] In various embodiments, the locking detent 5582 can engage
the distal attachment portion 5504 of the DLU 5502 to lock the DLU
5502 relative to the shaft 5520. For example, referring again to
FIG. 42, the distal attachment portion 5504 can include the guide
rail 5514, which can have a lock notch 5516 defined therein. The
lock notch 5516 can be structured and dimensioned to receive the
locking detent 5582 of the rotatable collar 5580 when the DLU 5502
is fully inserted into the proximal attachment portion 5522. For
example, when the distal attachment portion 5504 is fully inserted
into the proximal attachment portion 5522, the lock notch 5516 of
the distal attachment portion 5504 can be aligned with the detent
slot 5536 of the proximal attachment portion 5522. Accordingly, the
locking detent 5582 can slide along the detent slot 5536 in the
proximal attachment portion 5522 and into the lock notch 5516 in
the distal attachment portion. Furthermore, the locking detent 5582
can be biased toward engagement with the lock notch 5516 by the
torsion spring 5592. For example, after the firing shaft rotator
5544 clears the distal end 5509 of the rotation key 5506, the
firing shaft 5540 can be biased back toward the first orientation
and the rotatable collar 5580 can be biased back toward the initial
orientation by the torsion spring 5592. Furthermore, when the
collar 5580 is rotated from the secondary orientation back to the
initial orientation, the locking detent 5582 thereof can be aligned
and engaged with the lock notch 5516 in the guide rail 5514.
[0249] In various embodiments, rotation of the collar 5580 can
facilitate attachment and/or alignment of a firing assembly. For
example, the firing shaft 5540 can extend between a proximal end
5546 and a distal end 5542. The proximal end 5546 can have a
rotation joint, which can permit rotation of the firing shaft 5540
between the first configuration and the second configuration.
Furthermore, the distal end 5542 can have a coupler for attaching a
cutting element of the DLU 5502. Rotation of the firing shaft 5540
can facilitate attachment of the cutting element. For example, as
the coupler at the distal end 5542 of the firing shaft 5540
rotates, the coupler can engage and connect to the cutting element
in the DLU 5502. In certain embodiments, the coupler can include a
bayonet mount, which can engage a corresponding bayonet receiver of
the cutting element in the DLU 5502. Referring primarily to FIGS.
40 and 41, the firing assembly can further include a sleeve 5550
positioned around the firing shaft 5540 between the proximal end
5546 and the distal end 5542, for example.
[0250] In various embodiments, when the firing shaft 5540 rotates
within the shaft 5520, the firing shaft 5540 can rotate into
alignment with a firing shaft slot 5518 in the DLU 5502. For
example, the firing shaft rotator 5544 can be aligned with the
firing shaft slot 5518 when the DLU 5502 is fully inserted and
attached to the shaft 5520. However, in various embodiments, when
the DLU 5502 is only partially inserted into the shaft 5520, the
firing shaft rotator 5544 can be rotated, via the rotation key
5506, out of alignment with the firing shaft slot 5518. In other
words, the firing shaft rotator 5544 can be aligned with the firing
shaft slot 5514 when the firing shaft 5540 is in the first
orientation, and can be misaligned with the firing shaft slot 5514
when the firing shaft 5540 rotates toward the second orientation.
In such embodiments, when the DLU 5502 is only partially inserted
into the shaft 5520 and/or before the DLU 5502 is releasably locked
to the shaft 5520 by the rotatable collar 5580, the firing path of
the firing shaft rotator 5544 can be blocked by the distal
attachment portion 5504. Integration of the firing shaft 5540 and
the collar 5580 can ensure the DLU 5502 is securely attached to the
shaft 5520 before the firing shaft 5540 can fire and/or advance.
For example, the surgical instrument may be unable to fire until
the cutting element in the DLU 5502 is coupled to the firing shaft
5540, and/or until the firing shaft 5540 is properly aligned within
the shaft 5520, for example.
[0251] In certain embodiments, rotation of the collar 5580 can
facilitate attachment and/or alignment of an articulation assembly
5559. Referring primarily to FIGS. 40 and 41, the articulation
assembly 5559 can include a proximal articulation bar 5560, a
distal articulation bar 5562, and an articulation connector 5566.
Furthermore, the shaft 5520 can include a proximal articulation bar
slot 5528, and the DLU 5502 can include a distal articulation bar
slot 5512, for example. In certain embodiments, the proximal
articulation bar 5560 can be aligned with the proximal articulation
bar slot 5528, and the distal articulation bar 5562 can be aligned
with the distal articulation bar slot 5512. Referring now to FIG.
46, the articulation connector 5566 can be housed in the rotatable
collar 5580. For example, the rotatable collar 5580 can include an
articulation connector slot 5586, and the articulation connector
5566 can be moveably positioned therein.
[0252] In various embodiments, referring again to FIGS. 40 and 41,
the proximal articulation bar 5560 can have a proximal notch 5572,
and the distal articulation bar 5562 can have a distal notch 5574.
Furthermore, the articulation connector 5566 can include a proximal
articulation lug 5568 and a distal articulation lug 5572. The
proximal articulation lug 5568 can be retained in the proximal
notch 5572 of the proximal articulation bar 5560. In certain
embodiments, the distal articulation lug 5570 can operably engage
the distal notch 5574 of the distal articulation bar 5562. As
described herein, the rotatable collar 5580 can rotate between the
initial configuration and the secondary configuration. As the
collar 5580 rotates, the articulation connector 5566 housed therein
can also rotate relative to the longitudinal axis defined by the
shaft 5520. In various embodiments, the proximal articulation lug
5568 of the articulation connector 5566 can remain positioned in
the proximal notch 5572 of the proximal articulation bar 5560 as
the articulation connector 5566 rotates. Furthermore, the distal
articulation lug 5570 of the articulation connector 5566 can move
into engagement with the distal notch 5574 of the distal
articulation bar 5562 as the articulation connector 5566 rotates
with the collar 5580 from the secondary orientation toward the
initial orientation. For example, when the DLU 5502 is fully
inserted into the shaft 5508, the distal notch 5574 of the distal
articulation bar 5562 can be aligned with the distal articulation
lug 5568 of the articulation connector 5566. In such embodiments,
when the rotatable collar 5580 rotates back to the initial
configuration, the distal articulation lug 5568 can slide into the
distal notch 5574 of the distal articulation bar 5562. When the
distal articulation lug 5568 is positioned in the distal notch
5574, the articulation assembly 5559 can be fully assembled.
[0253] Referring primarily to FIG. 45, in various embodiments, the
proximal articulation bar slot 5528 can include a first clearance
5530 and a second clearance 5532. The proximal and distal
articulation lugs 5568, 5570 of the articulation connector 5566 can
extend into the first and second clearances 5530, 5532,
respectively. In certain embodiments, the first and second
clearances 5530, 5532 can provide a space for the proximal and
distal articulation lugs 5568, 5570 to move as the collar 5580
rotates and/or as the articulation assembly 5559 articulates, for
example.
[0254] Referring now to FIGS. 51-58, to connect the DLU 5502 to the
shaft 5520 of the surgical instrument, a user can align the
alignment indicia 5510 of the DLU 5502 with the alignment indicia
5590 of the shaft 5520 and/or the collar 5580 (FIG. 51). While
maintaining alignment of the alignment indicia 5510, 5590, the user
can move the DLU 5502 relative to the shaft 5520 along the
longitudinal axis defined by the shaft 5520. The user can move the
DLU 5502 along a straight or substantially straight path, and, in
various embodiments, need not rotate the DLU relative to the shaft
5520, for example. Referring primarily to FIG. 53, the DLU 5502 can
continue to translate relative to the shaft 5520, and the guide
rail 5514 of the distal attachment portion 5504 can fit into the
guide slot 5534 (FIG. 44) in the proximal attachment portion 5522
of the shaft 5520. As the distal attachment portion 5504 moves into
the proximal attachment portion 5522, the guide slot 5534 can guide
the guide rail 5514, and can maintain alignment of the alignment
indicia 5510, 5590, for example. In other words, the guide slot
5534 and the guide rail 5514 can prevent rotation of the DLU 5502
relative to the longitudinal axis of the shaft 5520. Referring
primarily to FIG. 52, the proximal articulation lug 5568 of the
articulation connector 5522 can extend into the first clearance
5530 and can be positioned in the proximal notch 5572 of the
proximal articulation bar 5562, and the distal articulation lug
5570 of the articulation connector 5522 can extend through the
second clearance 5532, for example.
[0255] Referring primarily to FIG. 54, as the distal attachment
portion 5504 is inserted into the proximal attachment portion 5522,
the rotation key ramp 5508 of the rotation key 5506 can abut the
firing shaft rotator 5544. The rotation key ramp 5508 can guide
and/or direct the firing shaft rotator 5544 into the clearance
notch 5526 extending from the rotation key slot 5524. Furthermore,
as the firing shaft rotator 5544 moves into the clearance notch
5526, the firing shaft 5540 can rotate in the direction B. The
firing shaft 5540 can rotate from the first orientation to the
second orientation. Such rotation of the firing shaft 5540 can
facilitate attachment of the distal end 5542 of the firing shaft
5540 with a cutting element in the DLU 5502. Furthermore, rotation
of the firing shaft rotator 5544 can rotate the collar 5580 in the
direction B via the engagement between the firing shaft rotator
5544 and the firing shaft rotator groove 5584 (FIG. 46) in the
collar 5580. The collar 5580 can rotate from the initial
orientation to the secondary orientation, for example.
Additionally, the locking detent 5582 can move along the detent
slot 5536 in the shaft 5520 as the collar 5580 rotates.
Additionally, rotation of the collar 5580 can rotate the distal end
5596 of the spring 5592 because the distal end 5596 of the spring
5592 can be retained in the distal spring slot 5588 (FIG. 46) in
the collar 5580. Displacement of the distal end 5596 relative to
the proximal end 5594 can generate a torsional springback force,
which can bias the collar 5580 from the secondary orientation
toward the initial orientation, for example, and can bias the
firing shaft 5540 from the second orientation toward the first
orientation, for example.
[0256] Referring primarily to FIG. 55, as the collar 5580 rotates
toward the secondary orientation, the proximal articulation lug
5568 can remain engaged with the proximal notch 5572 in the
proximal articulation bar 5560. Furthermore, the distal
articulation lug 5570 can rotate such that the distal articulation
lug 5570 provides a clearance for the distal articulation bar 5562
of the DLU 5502. Referring to FIG. 56, the DLU 5502 can be fully
inserted into the shaft 5520 when the collar 5580 and the
articulation connector 5566 positioned therein are rotated to the
secondary orientation. In various embodiments, the distal
articulation bar 5562 can clear the distal articulation lug 5570 of
the articulation connector 5566 when the articulation connector
5566 is rotated to the secondary orientation. Furthermore, the
distal articulation lug 5570 can be rotatably aligned with the
distal notch 5574 in the articulation connector 5566. Referring
still to FIG. 56, when the DLU 5502 is fully inserted into the
shaft 5520, the firing rod rotator 5544 can clear the distal end
5509 of the rotation key 5506.
[0257] Referring now to the FIG. 57, the firing shaft rotator 5544
can rotate in the direction C when the distal end 5509 of the
rotation key 5506 passes the firing shaft rotator 5544. For
example, the firing shaft rotator 5544 can rotate in direction C
from the second orientation toward the first orientation.
Furthermore, rotation of the firing shaft rotator 5544 can affect
rotation of the collar 5580 in the direction C from the secondary
orientation toward the initial orientation. In various embodiments,
the spring 5592 can bias the firing rod 5540 toward the first
orientation thereof and the collar 5580 toward the initial
orientation thereof. For example, the firing shaft rotator 5544 can
be positioned in the firing shaft rotator groove 5584 (FIG. 46) in
the collar 5580 such that rotation of the firing shaft rotator 5544
rotates the collar 5580. Due to the alignment of the distal
articulation lug 5570 of the articulation connector 5566 and the
distal notch 5574 of the distal articulation bar 5562, the
articulation connector 5566 can rotate as the collar 5580 rotates,
and the distal articulation lug 5570 can rotate into engagement
with the distal notch 5574. The articulation assembly 5559 can be
assembled when the distal articulation lug 5570 engages the distal
notch 5574. Furthermore, as the firing shaft rotator 5544 rotates
in direction C, the distal end 5542 of the firing shaft 5540 can
rotate in direction C, which can facilitate attachment of a cutting
element in the DLU 5502 to the distal end 5542 of the firing shaft
5540.
[0258] Referring now to FIG. 58, rotation of the collar 5580 can
also rotate the locking detent 5582 of the collar 5580 into the
lock notch 5516 in the guide rail 5514 of the distal attachment
portion 5504. For example, when the DLU 5502 is fully inserted into
the shaft 5520, the lock notch 5516 can be aligned with the detent
slot 5536 such that the locking detent 5582 can rotate through the
detent slot 5536 and into the lock notch 5516. As described herein,
the spring 5592 can bias the collar 5580 to rotate in the direction
C (FIG. 57) after the firing shaft rotator 5544 clears the distal
end 5509 of the rotation key 5506. Referring still to FIG. 58, when
the firing shaft rotator 5544 rotates in direction C, the firing
shaft rotator 5544 can move into alignment with the firing shaft
slot 5518 in the DLU 5502. Alignment of the firing shaft rotator
5544 with the firing shaft slot 5518 can permit the firing shaft
5540 to be advanced distally to fire the DLU 5502, for example.
[0259] As described herein, the rotatable collar 5580 can
releasably lock the DLU 5502 relative to the shaft 5520.
Furthermore, rotation of the collar 5580 can facilitate attachment
and/or alignment of the articulation assembly 5559, as well as
attachment and/or alignment of the firing shaft 5540 with a cutting
element in the DLU 5502, for example. Furthermore, rotation of the
collar can also unlock the DLU 5502 from the shaft, disconnect the
articulation assembly 5559, and/or disconnect the firing shaft 5540
from the cutting element in the DLU 5502. For example, when the
collar 5580 is again rotated from the initial orientation toward
the secondary orientation, the locking detent 5582 can disengage
the lock notch 5516 in the distal attachment portion 5504.
Accordingly, the distal attachment portion 5504 can be withdrawn
from the proximal attachment portion 5522 along the longitudinal
axis defined by the shaft 5520, for example. In various
embodiments, the DLU 5502 can be unattached from the shaft 5520
without rotating the DLU 5502 relative to the shaft 5520. However,
the collar 5580 can rotate relative to the shaft 5520, which can
disconnect the distal articulation bar 5562 from the articulation
connector 5566 in the collar 5580, and can disconnect the firing
shaft 5540 from the cutting element in the DLU 5502, for
example.
[0260] Referring now to FIGS. 59-62, a disposable loading unit
(DLU) or end effector 5602 can be releasably attached to a shaft
5620 of a surgical instrument. In various embodiments, a spring or
a plurality of springs, for example, can bias the DLU 5602 into a
locked positioned relative to the shaft 5620. For example, the DLU
5602 can be releasably attached to the shaft 5620 by a bayonet
mount, and a spring can rotate the DLU 5602 to connect the DLU 5602
to the shaft 5620 at the bayonet connection. The DLU 5602 can
include a distal attachment portion 5604, and the shaft 5620 can
include a proximal attachment portion 5622, for example. The distal
attachment portion 5604 of the DLU 5602 can receive the proximal
attachment portion 5622 of the shaft 5620 when the DLU 5602 is
secured to the shaft 5620. In other embodiments, a proximal
attachment portion of the shaft 5620 can receive a distal
attachment portion of the DLU 5602 when the DLU 5602 is secured to
the shaft 5620.
[0261] In various embodiments, the distal attachment portion 5604
of the DLU 5602 can include a detent 5606, which can extend
radially outward from a portion of the distal attachment portion
5604. Furthermore, the detent 5606 can include a ramped surface
5608. As described herein, the ramped surface 5608 of the detent
5606 can engage a spring, such as spring 5636b, for example, and
can deform the spring 5636b when the distal attachment portion 5604
is inserted into the proximal attachment portion 5622. Furthermore,
the detent 5606 can be held by the proximal attachment portion 5622
to releasably lock the DLU 5602 to the shaft 5622. Referring
primarily to FIG. 59, the proximal attachment portion 5622 of the
shaft 5620 can define a cavity 5624. In various embodiments, the
cavity 5624 can be structured and dimensioned to receive the distal
attachment portion 5604 of the DLU 5602. Furthermore, a spring
5636a, 5636b can be positioned within the cavity 5624. For example,
a first spring 5636a can be positioned on a first side of the
cavity 5624, and a second spring 5636b can be positioned on a
second side of the cavity 5624. The springs 5636a, 5636b can be
symmetrical or non-symmetrical relative to the cavity 5624. In
various embodiments, at least a portion of a spring 5636a, 5636b
can extend into the cavity 5624. For example, a leg 5637 of the
second spring 5636b can extend into the cavity 5624, and another
leg 5637 of the second spring 5636 can be retained in the proximal
attachment portion 5622, for example.
[0262] Referring still to FIG. 59, the proximal attachment portion
5622 can also include a lock slot 5638, which can be defined in the
cavity 5624 and/or can be accessible via the cavity 5624, for
example. The lock slot 5638 can be structured and dimensioned to
receive the detent 5606, for example. In various embodiments, the
lock slot 5638 can hold the detent 5606 to releasably lock the DLU
5602 relative to the shaft 5620. Furthermore, in various
embodiments, the proximal attachment portion 5622 can include a
latch 5630. The latch 5630 can be moveable between an unlatched
position (FIGS. 59 and 60) and a latched position (FIGS. 61 and
62). In various embodiments, the latch 5630 can be spring-loaded,
and the spring 5634 can bias the latch 5630 into the latched
position. For example, the latch 5630 can include a latch spring
5634, which can bias the latch 5630 toward and/or into the latched
position. The latched position can be distal to the unlatched
position, for example. In certain embodiments, the latch 5630 can
include a thumb grip and/or ridges 5632 to facilitate movement of
the latch 5630 from the latched position to the unlatched position.
For example, a user can engage the thumb grip 5632 and draw the
latch 5630 proximally to unlatch the latch 5630.
[0263] In various embodiments, the latch 5630 can operably block or
at least partially block the lock slot 5638. For example, when the
latch 5630 is in the latched position (FIGS. 61 and 62), an arm
5635 of the latch 5630 can extend over at least a portion of the
lock slot 5638. The latch 5630 can cover or partially cover the
lock slot 5638, and can prevent and/or limit access to the lock
slot 5638. In certain embodiments, the arm 5635 of the latch 5630
can prevent the detent 5606 from moving and/or sliding into the
lock slot 5638. Moreover, when the latch 5630 is in the latched
position, the latch 5630 can engage the spring 5636a, 5636b. For
example, referring to FIGS. 61 and 62, the latch 5630 can support
the spring 5636b, such that deformation of the spring 5636b is
limited and/or prevented. Furthermore, the latch 5630 can support
the spring 5636b such that the cavity 5624 cannot receive the
distal attachment portion 5604 of the DLU 5602. For example, at
least a portion of the spring 5636b can block the cavity 5624,
which can prevent complete insertion of the distal attachment
portion 5604 into the proximal attachment portion 5622. In certain
embodiments, the proximal attachment portion 5622 can include a
plurality of springs, which can exert a rotational force on the
distal attachment portion 5604 to rotate the distal attachment
portion 5604 relative to the proximal attachment portion 5622. For
example, the proximal attachment portion 5622 can include a pair of
springs or more than three springs. In other embodiments, a single
spring in the proximal attachment portion 5622 can seek to rotate
the distal attachment portion 5604 relative to the proximal
attachment portion 5622. Additionally or alternatively, in various
embodiments, the distal attachment portion 5602 of the DLU 5602 can
include at least one spring, which can rotate the distal attachment
portion 5602 relative to the proximal attachment portion 5622, for
example.
[0264] In various embodiments, when the latch 5630 is in the
unlatched position (FIGS. 59 and 60), the lock slot 5638 can be
unblocked and/or less blocked by the arm 5635 of the latch 5630.
For example, the detent 5606 can fit past the unlatched latch 5630
to fit into the lock slot 5638. Furthermore, the detent 5606 can be
biased past the unlatched latch 5630 and into the lock slot 5638,
as described herein. Moreover, in various embodiments, when the
latch 5630 is in the unlatched position, the latch 5630 can
disengage the spring 5636a, 5636b. For example, the latch 5630 may
not protect and/or limit deformation of the spring 5636a, 5636b
when the latch 5630 is unlatched.
[0265] Referring primarily to FIG. 59, when the latch 5630 is moved
and held in a proximal and/or unlatched position, for example, the
spring 5636b can be unsupported by the latch 5630. In such
embodiments, the DLU 5602 can be moved in the direction A such that
the distal attachment portion 5604 is moved relative to the
proximal attachment portion 5622. Referring primarily to FIG. 60,
the detent 5606 of the distal attachment portion 5604 can engage
the spring 5636b, and can compress and/or deform the spring 5636b,
for example. In certain embodiments, the ramped surface 5608 of the
detent 5606 can slide along the spring 5636b, and can move the free
leg 5637 of the spring 5636b. Deformation of the spring 5636b can
generate a springback force, which the spring 5636b can exert on
the detent 5606. Referring now to FIG. 61, the springback force can
affect rotation of the detent 5606. For example, the detent 5606
can rotate in direction B into the lock slot 5638 defined in the
cavity 5624. In various embodiments, the latch spring 5634 can
return the latch 5630 to the unlatched position when the user
releases the latch 5630. Furthermore, when the latch 5630 returns
to the unlatched position, the arm 5635 of the latch 5630 can block
or partially block the lock slot 5638. In such embodiments, the
detent 5606 of the distal attachment portion 5604 can be releasably
locked relative to the proximal attachment portion 5622 when the
detent 5606 is held in the lock slot 5638. Furthermore, in certain
embodiments, the latch 5630 can hold and/or support the spring
5636b against the detent 5606 until the latch is again moved to the
unlatched position. In various embodiments, to release the DLU 5602
from the shaft 5620, a user can again move the latch 5630 from the
latched position to the unlatched position, such that the detent
5606 can be rotated out of the lock slot 5638. In such embodiments,
the rotation of the detent 5606 again compresses and/or deforms the
spring 5636b until the distal attachment portion 5604 is withdrawn
from the proximal attachment portion 5622.
[0266] Further to the above, the surgical instrument can be
configured to identify, or at least attempt to identify, the end
effector that has been assembled to the surgical instrument. In
certain embodiments, as described in greater detail further below,
the end effector can include electrical contacts which can engage
corresponding electrical contacts on the shaft of the surgical
instrument when the end effector is assembled to the shaft. In such
embodiments, the controller of the surgical instrument can
establish a wired connection with the end effector and signal
communication between the controller and the end effector can occur
through the electrical contacts. As described in greater detail
below, the end effector can include at least one datum stored
thereon which can be accessed by the controller to identify the end
effector. The at least one datum can include a bit, more than one
bit, a byte, or more than one byte of information, for example. In
certain other embodiments, the end effector can include a
transmitter which can be in wireless signal communication with the
controller of the surgical instrument. Similar to the above, the
end effector can include at least one datum stored thereon which
can be transmitted to the controller to identify the end effector.
In such embodiments, the controller of the surgical instrument can
include a receiver, or utilize a receiver, which can receive the
transmission from the end effector. Such a receiver can be
positioned in the shaft and/or the handle of the surgical
instrument, for example.
[0267] As the reader will appreciate, an end effector which
communicates wirelessly with the controller, for example, can be
configured to emit a wireless signal. In various circumstances, the
end effector can be configured to emit this signal once or more
than once. In certain circumstances, the end effector can be
prompted to emit the signal at a desired moment and/or repeatedly
emit the signal in a continuous manner. In some circumstances, the
end effector can include a switch which can be operated by the user
of the surgical instrument before, during, and/or after the end
effector of the surgical instrument is assembled to the surgical
instrument. In various embodiments, the end effector switch can
comprise an on/off, or power, switch which can be closed, or
operated, to activate the end effector. In at least one such
embodiment, the end effector can include at least one power source,
such as a battery, for example, which can be utilized by the
transmitter to emit the signal when the on/off switch is closed.
Upon activation of the end effector, in various circumstances, the
controller of the end effector can be configured to generate the
signal and emit the signal via the transmitter. In some
circumstances, the end effector may not emit the signal until the
end effector is activated. Such an arrangement can conserve the
power of the battery, for example. In certain embodiments, the
surgical instrument can be placed in an operating mode where it can
await the signal from the end effector before the end effector
switch is actuated. In various circumstances, the surgical
instrument can be in a standby, or low-power, operating mode
wherein, once the signal has been received by the controller, the
controller can place the surgical instrument in a fully-powered
operating mode. In some embodiments, the end effector switch can
instruct an end effector controller to emit the signal to the
surgical instrument controller. Such a switch may or may not
comprise a power switch; however, such a switch could be
selectively actuated by the user to prompt the end effector to emit
the signal at a desired moment and/or continuously from a desired
moment forward.
[0268] Turning now to FIG. 114, an end effector, such as end
effector 9560, for example, can include one or more electrical
contacts, such as contacts 9561, for example, which can be utilized
to activate the end effector 9560. For instance, turning now to
FIG. 112, the shaft 9040 of the surgical instrument can include a
contact bridge 9562 which can be configured to short, or
electrically connect, two or more of the contacts 9561 when the end
effector 9560 is assembled to the shaft 9040. The bridge 9562 can
complete a circuit including two contacts 9561, a battery 9564, and
at least one integrated circuit 9566 defined on a printed circuit
board 9565. Once the circuit is completed, further to the above,
the battery 9564 can power the integrated circuit, or circuits,
9566 and the end effector 9560 can be activated. In various
circumstances, the integrated circuit, or circuits, 9566 and an
antenna 9567 defined on the printed circuit board 9565 can comprise
the controller and transmitter discussed above. In certain
embodiments, the shaft 9040 can include a biasing member, such as a
spring 9563, for example, which can be configured to bias the
bridge 9562 into contact with the electrical contacts 9561. Prior
to the bridge 9562 connecting the electrical contacts 9561 and/or
after the end effector 9560 has been detached from the shaft 9040,
the circuit can be open, power from the battery 9564 may not be
supplied to the integrated circuit 9566, and/or the power supplied
to the integrated circuit 9566 may be reduced, and the end effector
9560 can be in an inactivated condition. As a result of the above,
in such embodiments, the assembly of the end effector can be
activated as a result of assembling the end effector to the
surgical instrument. In various instances, further to the above,
the end effector and the surgical instrument can be constructed and
arranged such that only the complete and proper assembly of the end
effector to the surgical instrument will activate the end
effector.
[0269] As discussed above, referring now to FIG. 111, an end
effector can be attached to the surgical instrument, indicated by
step 9600, activated, indicated by step 9602, and then evaluated by
the surgical instrument, indicated by step 9604. When the surgical
instrument is attempting evaluate a wireless signal from an
activated end effector, further to the above, the surgical
instrument can be configured to assess whether the signal is
complete. In various embodiments, asynchronous serial communication
between the end effector and the surgical instrument can be
utilized to assess whether the signal received by the surgical
instrument is complete. For instance, the end effector can emit a
signal comprising a start bit which precedes a frame of data, such
as a byte of information, for example, and/or a stop bit which
follows the frame of data. In such instances, the start bit, the
byte of data, and the stop bit can comprise a 10-bit character
frame, or bit pattern, for example. When the controller of the
surgical instrument can identify the start bit and the stop bit of
a bit pattern, in such instances, the controller can assume that
the byte of data, or the bits of data, received between the start
bit and the stop bit is correct and/or otherwise complete. In
various circumstances, the start bit and/or the stop bit can
comprise a stop period before the next byte of information is
transmitted and/or before the previous byte of information is
communicated once again.
[0270] Further to the above, turning now to FIG. 110, the
controller of the surgical instrument can compare the bit pattern,
or certain bits of the data, to determine whether the data that it
has received is correct and/or otherwise complete. In various
circumstances, the data can be transmitted in such a way that the
controller can evaluate the data and compare the data to a bit
pattern template, or templates, in which it was expecting to
receive the data. For instance, such a template can be configured
and arranged such that the most significant bit of data, such as
the left-most bit of data, for example, comprises a 1, for example.
In the event that the controller is able to identify that the most
significant bit of data equals a 1, referring to step 9700 in FIG.
110, the controller can perform a XOR operation on the data and
compare the data to the bit pattern template, or templates,
available to the controller, as indicated in step 9702. An XOR
operation is known and a detailed discussion of the same is not
provided herein for the sake of brevity. In the event that the bit
pattern received by the surgical instrument matches a bit pattern
template available to the controller, the controller will have
identified the end effector. Upon identifying the end effector, the
controller can access stored information regarding the end effector
in a memory chip accessible by the controller, for example. In the
event that the controller determines that the most significant bit
of data in the received bit pattern does not equal a 1, referring
again to step 9700, the controller can perform a bit shift
operation. Many bit shift operations are known, such as arithmetic
shifts, logic shifts, and/or circular shifts, for example, which
can be utilized to eliminate bad data bits which were received
prior to the desired bit pattern. In various circumstances, the
leading, or left-most, 0 data bits can be eliminated, referring now
to step 9704 in FIG. 110, and the bit pattern can be shifted to the
left, for example, until the leading bit is a 1. At such point,
further to the above, the shifted bit pattern can be compared to
the bit pattern templates in order to identify the end effector. In
the event that shifted bit pattern does not match a bit pattern
template, the controller can shift the bit pattern once again until
the next 1 in the bit pattern becomes the leading bit and the new
shifted bit pattern can be compared to the bit pattern templates.
Such a shifting and comparing operation can be performed any
suitable number of times until the end effector is identified
and/or the surgical instrument deems that the end effector is
unidentified.
[0271] As the reader will appreciate, a surgical instrument can
include information regarding any suitable number of end effectors.
When an end effector has been identified by the surgical
instrument, further to the above, the surgical instrument can
access stored information relating to the end effector. For
instance, such stored information can instruct the surgical
instrument as to, one, the distance in which a firing member in the
end effector must be advanced to complete a firing stroke and/or,
two, the maximum amount of power or torque that the motor of the
surgical instrument should apply to the firing member, for example.
Such information, or a set of information, may be unique to each
end effector and, accordingly, identifying the end effector in some
way is what allows the surgical instrument to operate in a desired
manner. Without such information, the surgical instrument may not
be able to discern the stroke length required to fully utilize the
end effector and/or appropriately limit the power that it applies
to the firing member. In various circumstances, the surgical
instrument may rely on sensors configured to detect when the firing
stroke has been completed and/or whether the power being applied to
the firing member is excessive. Such sensors may prevent the motor
of the surgical instrument from overpowering and damaging the
firing member, for example, of the end effector.
[0272] Further to the above, certain end effectors may be more
robust than other end effectors and, as a result, certain end
effectors may be able to withstand larger forces from the motor of
the surgical instrument. Correspondingly, other end effectors may
be less robust and, as a result, may be only able to withstand
smaller forces from the motor. In order for the surgical instrument
to determine the appropriate forces to apply to any specific end
effector, further to the above, the surgical instrument must
identify the end effector attached to the surgical instrument. In
the event that the end effector cannot identify the end effector,
the surgical instrument can utilize a default operating program, or
mode. In the default operating mode, the controller of the surgical
instrument may limit the power that the motor can apply to the
firing member of the end effector, for example, to a minimum, or
default, power. The minimum power can be selected such that the
motor will not damage an end effector regardless of the end
effector that is being used. In some circumstances, the parameters
for utilizing the weakest, or least robust, end effector that can
be used with the surgical instrument can be utilized by the default
operating mode such that the surgical instrument will not overpower
the end effector regardless of the end effector being used. In
various instances, it is the advent of motor-powered surgical
instruments that may cause an end effector to be overpowered.
Stated another way, end effectors that were previously used by
hand-driven surgical instruments, and essentially unbreakable by
such hand-driven surgical instruments, may be easily breakable by a
motor-powered surgical instrument. Moreover, such previous end
effectors may not include the technology to be identified by the
motor-driven surgical instruments and, as a result of the default
operating program described herein, such previous end effectors may
still be used even with the motor-driven surgical instruments. That
said, the default operating program can also utilize other default
parameters. For instance, the default operating program can utilize
a minimum, or default, firing stroke length. In various instances,
the default operating program can utilize the shortest stroke
length of the end effector that can be used with the surgical
instrument. In such instances, the firing member will not collide,
or crash, with the distal end of the end effector regardless of the
end effector being used.
[0273] As the reader will appreciate, a surgical instrument which
includes stored information regarding the end effectors that can be
used with the surgical instrument, the information available to the
surgical instrument may need to be updated. For instance, if the
preferred operating parameters with regard to a certain end
effector change over time, the information stored within each
surgical instrument may need to be updated. Furthermore, for
instance, the surgical instruments may need to be updated when a
new end effector is developed for use with the surgical
instruments. To the extent that the surgical instrument is not
updated in a timely manner, the surgical instrument may not be able
to identify the end effector and, as a result, may use the default
operating program described herein. In various embodiments, a
surgical instrument may not include stored information regarding
the end effectors, or at least certain end effectors, that can be
used with the surgical instrument. In such embodiments, an end
effector can include stored information, or parameters, related to
the end effector. Such parameters can be accessed by and/or
communicated to the surgical instrument. In various circumstances,
further to the above, the assembly of an end effector to the
surgical instrument can cause the end effector to emit a signal
which can be received by the surgical instrument. Also similar to
the above, the end effector can be prompted to emit the signal.
This signal, in various circumstances, can be transmitted to the
surgical instrument via a wired and/or a wireless connection. In
certain embodiments, the surgical instrument can prompt the end
effector to transmit the signal.
[0274] Further to the above, an end effector can include one or
more parameters regarding the end effector stored therein. Such
parameters can be stored on one or more memory devices, for
example. In various instances, such parameters can include the
desired firing speed of the firing member, the desired retraction
speed of the firing member, the distance or stroke in which the
firing member is to travel, the maximum torque to be applied to the
firing member by the motor of the surgical instrument, and/or the
maximum angle in which the end effector is to be articulated if the
end effector is, in fact, an articulating end effector, for
example. Certain articulating end effectors are disclosed in U.S.
patent application Ser. No. 13/803,097, entitled ARTICULATABLE
SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, the entire
disclosure of which is incorporated by reference herein. With
regard to the parameter related to the maximum articulation angle,
the controller can utilize this parameter to limit the degree in
which the articulatable portion of the end effector is articulated.
In some instances, the maximum articulation angle can be 45
degrees, for example, as measured from the longitudinal axis of the
surgical instrument shaft. With regard to the parameter related to
the firing speed and/or the retraction speed of the firing member,
for example, the parameter can communicate a desired speed for the
firing member and/or a percentage or fraction of the maximum speed
of the motor, for example. For instance, a value of 3 for the
firing speed could communicate that the controller should operate
the motor at 30% of its maximum speed, for example, when advancing
the firing member. Also, for instance, a value of 5 for the
retraction speed could communicate that the controller should
operate the motor at 50% of its maximum speed, for example, when
retracting the firing member. With regard to the parameter related
to the maximum torque of the motor, for example, the parameter can
communicate a maximum value of the torque and/or a percentage or
fraction of the maximum torque of the motor, for example.
Furthermore, with regard to the parameter related to the stroke
length of the firing member, for example, the parameter can
communicate the desired distance in which the firing member is to
be advanced and/or retracted and/or a percentage or fraction of the
maximum stroke length of the surgical instrument. For instance, a
value of 60 could indicate that the firing stroke should be 60 mm,
for example. In various instances, the values of the parameters can
be communicated in any suitable format, including a binary format
comprising bits and/or bytes of data, for example. An exemplary
embodiment of a parameter array is depicted in FIG. 110A.
[0275] In various embodiments, further to the above, the surgical
instrument can be configured to obtain the parameters from the end
effector in a specific order. For instance, a signal emitted from
the end effector can comprise a start bit, a first bit pattern for
a first parameter, such as the maximum articulation angle, a second
bit pattern for a second parameter, such as the firing speed, a
third bit pattern for a third parameter, such as the retraction
speed, a fourth bit pattern for a fourth parameter, such as the
maximum motor torque, a fifth bit pattern for a fifth parameter,
such as the stroke length, and a stop bit, for example. This is but
one example. Any suitable number of parameters may be communicated
as part of the signal. Furthermore, any suitable number of start
bits and/or stop bits may be utilized. For instance, a start bit
may precede each parameter bit pattern and/or a stop bit may follow
each parameter bit pattern. As discussed above, the utilization of
at least one start bit and/or at least one stop bit can facilitate
the controller of the surgical instrument in analyzing whether the
signal from the end effector is complete. In certain embodiments, a
start bit and/or a stop bit may not be utilized. Moreover, a
plurality of signals can be emitted from the end effector in order
to communicate parameters of the end effector to the surgical
instrument.
[0276] In various circumstances, further to the above, the
controller of the surgical instrument can utilize a checksum to
assess whether the signal it has received from an end effector is
complete, and/or whether the signal it has received is authentic,
i.e., from a recognized end effector. A checksum can comprise a
value used to ensure data are stored, transmitted, and/or received
without error. It can be created by calculating the binary values,
for example, of data and combining the binary values together using
some algorithm. For instance, the binary values of the data can be
added together, although various other algorithms could be
utilized. In embodiments where parameters regarding certain end
effectors are stored in the surgical instrument, as discussed
above, a checksum value can also be stored for each such end
effector. In use, the controller of the surgical instrument can
access the parameter data and the checksum value and, after
computating a checksum value from the parameter data, i.e.,
computating a calculated checksum value, the controller can compare
the calculated checksum value to the stored checksum value. In the
event that the calculated checksum value equals the stored checksum
value, the controller can assume that all of the data retrieved
from the memory of the surgical instrument is correct. At such
point, the controller can then operate the surgical instrument in
accordance with the data uploaded from the memory. In the event
that the calculated checksum value does not equal the stored
checksum value, the controller can assume that at least one datum
of the retrieved data is incorrect. In various instances, the
controller can then operate the surgical instrument under the
default operating program, further to the above, lockout the firing
trigger of the surgical instrument, and/or otherwise communicate
the event to the user of the surgical instrument, for example. In
certain instances, the controller can re-attempt to upload the data
from the memory of the surgical instrument and re-perform the
checksum computation and comparison discussed above. In the event
that the re-calculated checksum value and the stored checksum value
match, the controller can then operate the surgical instrument in
accordance with the data uploaded from the memory. In the event
that re-calculated checksum value and the stored checksum value are
not equal, the controller can then operate the surgical instrument
under the default operating program, further to the above, lockout
the firing trigger of the surgical instrument, and/or otherwise
communicate the event to the user of the surgical instrument, for
example.
[0277] In embodiments where parameters regarding an end effector is
stored in the memory of the end effector, as discussed above, a
checksum value can also be stored in the memory of the end
effector, for example. In use, the controller of the surgical
instrument can access the parameter data and the stored checksum
value. In various instances, further to the above, the end effector
can emit one or more signals that communicates the parameters and
the checksum value to the surgical instrument. As a result of the
above, the stored checksum value and the parameters can be
transmitted together and, for the purposes of discussion herein,
the checksum value received by the surgical instrument can be
referred to as the received checksum value. Once the parameter data
has been received, similar to the above, the controller can
computate a checksum value from the parameter data, i.e., computate
a calculated checksum value, and compare the calculated checksum
value to the received checksum value. In the event that the
calculated checksum value equals the received checksum value, the
controller can assume that all of the parameter data retrieved from
the end effector is correct. At such point, the controller can then
operate the surgical instrument in accordance with the data
uploaded from the end effector. In the event that the calculated
checksum value does not equal the received checksum value, the
controller can assume that at least one datum of the retrieved data
is incorrect. In various instances, the controller can then operate
the surgical instrument under the default operating program,
further to the above, lockout the firing trigger of the surgical
instrument, and/or otherwise communicate the event to the user of
the surgical instrument, for example. Such occurrences may be more
frequent when the parameter data is communicated from the end
effector to the surgical instrument via one or more wireless
transmissions, for example. In any event, in certain instances, the
controller can re-attempt to upload the data from the end effector
and re-perform the checksum computation and comparison discussed
above. In the event that the re-calculated checksum value and the
received checksum value match, the controller can then operate the
surgical instrument in accordance with the data uploaded from the
end effector. In the event that the re-calculated checksum value
and the received checksum value are not equal, the controller can
then, further to the above, operate the surgical instrument under
the default operating program, lockout the firing trigger of the
surgical instrument, and/or otherwise communicate the event to the
user of the surgical instrument, for example. In various instances,
as a result of the above, the surgical instrument does not need to
store any information regarding the end effectors that are used to
operate the surgical instrument when using the end effector. In
such instances, the data regarding the parameters of an end
effector, and the checksum value used to confirm the integrity of
the data, can be entirely stored on the end effector. The surgical
instrument can include an operating program that only requires
sufficient input from the end effector in order to use the end
effector. A specific operating program for each end effector that
can be used with the surgical instrument may not be required. A
single operating program can be used with every end effector. As
such, the surgical instrument may not need to be updated to include
operating programs for additional end effectors and/or modified
programs for existing end effectors, for example.
[0278] In addition to or in lieu of the wireless communication
systems utilized to identify the end effector attached to the
surgical instrument discussed herein, turning now to FIGS. 149-154,
a surgical instrument, in accordance with at least one embodiment,
can include means for scanning and identifying an end effector.
FIG. 153 illustrates a handle 11020 including a bar code reader
11022 which can be configured to scan a bar code, illustrated in
FIGS. 149 and 150, on an end effector 11060, illustrated in FIGS.
151, 152, and 154. Similar to other embodiments disclosed herein,
the end effector 11060 can include a shaft portion, an anvil 11062,
and/or a staple cartridge 11064, for example, wherein one or more
portions of the end effector 11060 can include a bar code thereon.
In some embodiments, the end effector 11060 can include a removable
component 11063 positioned intermediate the anvil 11062 and the
staple cartridge 11064 which can be removed prior to or after the
end effector 11060 has been assembled to the surgical instrument.
In FIG. 151, a bar code 11065 is depicted as being positioned on
the shaft portion of the end effector 11060. In FIG. 152, a bar
code 11065 is depicted as being positioned on the removable
component 11063. In various embodiments, the handle 11020 of the
surgical instrument can include a bar code reader, such as bar code
reader 11024, for example, configured to read a bar code on an end
effector. For instance, referring primarily to FIG. 154, the handle
11020 can include an internal bar code reader portion 11022
configured to read the bar code 11065 defined on the shaft of end
effector 11060. In at least one such instance, the bar code reader
portion 11022 can include a trough 11026 sized and configured to
receive the shaft of the end effector 11060 wherein the bar code
reader 11024 can be mounted within and/or relative to an opening
11027 defined in the trough 11026 such that the bar code reader
11024 can read the bar code 11065. As the reader will appreciate, a
multitude of bar code readers and bar code protocols are known, and
any suitable ones can be utilized. In some instances, a bar code
can include bi-directional information which allows the bar code to
be read in two different directions, for example. In some
instances, a bar code can utilize multiple layers of information.
In some instances, the bar code protocol can include preamble
information preceding information which will identify the end
effector and/or otherwise supply information to the surgical
instrument which will allow the surgical instrument to operate, or
operate using a specific operating program. In some instances, a
bar code reader can emit one or more light beams which can contact
a plurality of peaks and valleys which comprise the bar code. In
some instances, the valleys of the bar code can extend into, and/or
be defined within, the shaft housing of the end effector. The
emitted light beams can be reflected back to the bar code reader
where they can be interpreted. That said, the bar code reader 11024
of the handle 11020 is positioned and arranged within the trough
11026 such that the emitted and reflected light beams are confined,
or at least substantially confined, within the bar code reader
portion 11022. In this way, the bar code reader 11024 may not
accidentally or unintentionally scan a different end effector,
i.e., an end effector other than the one that is going to be
assembled to the surgical instrument, which may be present in the
surgical suite.
[0279] In various instances, further to the above, an end effector
can be passed through the bar code reader of a surgical instrument
before the end effector is assembled to the surgical instrument. In
various alternative embodiments, the surgical instrument can
include a movable bar code reader which can be utilized to scan the
bar code of the end effector after the end effector has been
assembled to the surgical instrument. In any event, once the end
effector has been identified, in at least some circumstances, the
controller can access an operating program configured to use the
identified end effector. In a way, the bar code can comprise a boot
loader. In other circumstances, as outlined elsewhere herein, the
bar code can supply the controller with the necessary information,
or parameters, to utilize a common operating system. In some
circumstances, each end effector can be identified with a
serialized number such that any two end effectors, eventhough they
may be the same type of end effector, may have two different bar
codes thereon. In such circumstances, the controller can be
configured to refuse to use an end effector that has been
previously scanned by the surgical instrument. Such a system could
prevent an at least partially expended end effector from being used
again, for instance.
[0280] As discussed above, an end effector can be configured to
communicate with a surgical instrument through a wired connection
and/or a wireless connection. With regard to a wired connection,
turning now to FIG. 115, the proximal end of an end effector, such
as proximal end 9969 of end effector 9960, for example, can
comprise a plurality of electrical contacts 9968 which can be
placed in electrical communication with a plurality of electrical
contacts 9948 arranged on and/or within a distal end 9942 of a
shaft 9940 of a surgical instrument. Referring primarily to FIG.
116, each electrical contact 9968 can include a contact element
9967 at least partially positioned within an element cavity 9965.
Each electrical contact 9968 can further include a biasing member,
such as a spring 9966, for example, positioned intermediate the
contact element 9967 and an interior sidewall of the element cavity
9965. The spring 9966 can be configured to bias the contact element
radially outwardly. The contact element 9967 can comprise a stop
9964 protruding therefrom which can be movably biased into
engagement with another interior sidewall of the element cavity
9965 by the spring 9966, at least prior to the end effector 9960
being assembled to the shaft 9940. The interaction between the stop
9964 and the sidewall of the element cavity 9965 can arrest the
outward movement of the contact element 9967. When the end effector
9960 is assembled to the shaft 9940, the contact elements 9967 of
the electrical contacts 9968 can be pushed inwardly by the shaft
electrical contacts 9948 against the biasing force applied by the
springs 9966, as illustrated in FIG. 116. In various circumstances,
each pair of contacts 9948 and 9968 can complete a circuit, or
communication channel 9950. While three pairs of contacts are
illustrated, any suitable number of contacts and/or communication
channels could be utilized. In various embodiments, referring to
FIG. 117, shaft contacts 10048 can each comprise a movable element
10047 and a biasing spring 10046 configured to push the movable
elements 10047 against the corresponding end effector contacts
10068. In certain embodiments, turning now to FIG. 118, one or both
of the end effector contacts and the shaft contacts can comprise a
flexible portion. For instance, an end effector can comprise
flexible contacts 10168 which can resiliently engage the
corresponding shaft contacts 9948.
[0281] With regard to the embodiments described above, in various
circumstances, the end effector can be assembled to the shaft along
a longitudinal axis. In such circumstances, referring primarily to
FIG. 115, the proximal-most end effector contact 9968 will first
come into electrical contact with the distal-most shaft contact
9948. As the reader will appreciate, the end effector 9960 has not
been completely attached to the shaft 9940 when such contacts come
into engagement. While such an engagement between these contacts
may be temporary, i.e., until the end effector 9960 is seated
deeper into the shaft 9940, the surgical instrument controller can
become confused and misinterpret one or more signals from the end
effector 9960. Similar confusion may arise as the longitudinal
array of end effector contacts 9968 progressively comes into
contact with the longitudinal array of shaft contacts 9948 until
the end effector 9940 is fully seated. In various embodiments, the
controller of the surgical instrument can be configured to ignore
the signals transmitted through the contacts until the
proximal-most end effector contact 9968 is engaged with the
proximal-most shaft contact 9948. Turning now to FIGS. 119 and 120,
one of the contact pairs may be different than the other contact
pairs such that the controller can identify when that pair of
contacts has been mated and, as a result, the end effector has been
completely seated. For instance, an end effector and a shaft of a
surgical instrument can include a first pair of contacts 10248a,
10268a, a second pair of contacts 10248b, 10268b, and a third pair
of contacts 10248c, 10268c wherein the third pair of contacts can
be different than the first pair of contacts and the second pair of
contacts. When the first pair of contacts 10248a, 10268a have been
mated, a contact element 10267a can be pushed inwardly such that a
first connection portion 10263a of the contact element 10267a comes
into contact with a first path portion 9951a of a communication
path 9950a and a second connection portion 10264a of the contact
element 10267a comes into contact with a second path portion 9952a
of the communication path 9950a. In such a position of the contact
element 10267a, the first path portion 9951a and the second path
portion 9952a can both transmit a signal through the contact
element 10267a. When the second pair of contacts 10248b, 10268b
have been mated, a contact element 10267b can be pushed inwardly
such that a first connection portion 10263b of the contact element
10267b comes into contact with a first path portion 9951b of a
communication path 9950b and a second connection portion 10264b of
the contact element 10267b comes into contact with a second path
portion 9952b of the communication path 9950b. In such a position
of the contact element 10267b, the first path portion 9951b and the
second path portion 9952b can both transmit a signal through the
contact element 10267b. When the third pair of contacts 10248c,
10268c have been mated, a contact element 10267c can be pushed
inwardly such that a first connection portion 10263c of the contact
element 10467c is out of contact with a first path portion 9951c of
a communication path 9950c and a second connection portion 10264c
of the contact element 10267c comes out of contact with a second
path portion 9952c of the communication path 9950c and into contact
with the first path portion 9951c. In such a position of the
contact element 10267a, the first path portion 9951c can transmit a
signal through the contact element 10267c. As a result of the
above, the first, second, and third sets can have a specific
arrangement of connectivity with their respective channel paths
when the end effector has been fully seated and the controller can
be configured to evaluate whether this fully-engaged arrangement is
in place. For instance, when the end effector is initially inserted
into the shaft, the third contact 10264c may initially come into
contact with the first shaft contact 10248a. In such a position,
only two path portions, i.e., 9951a and 9952a, may be able to
communicate a signal from the end effector to the controller and,
as a such, the controller can be configured to detect a different
voltage drop across the interconnection as compared to the voltage
drop that occurs when five path portions, i.e., 9951a, 9952a,
9951b, 9952b, and 9951c, are able to communicate the signal when
the end effector is fully seated. Similarly, the end effector can
be further inserted into the shaft until the third contact element
10267c comes into contact with the second shaft contact 10248b and
the second contact element 10267b comes into contact with the first
shaft contact 10248a. In such a position, only four path portions,
i.e., 9951a, 9952a, 9951b, and 9952b may be able to communicate a
signal from the end effector to the controller and, as a such, the
controller can be configured to detect a different voltage drop
across the interconnection as compared to the voltage drop that
occurs when five path portions, i.e., 9951a, 9952a, 9951b, 9952b,
and 9951c, are able to communicate the signal when the end effector
is fully seated.
[0282] In certain instances, when an end effector is assembled to
an elongate shaft of a surgical instrument, the operator can engage
the drive system and/or the articulation system of the end effector
to initiate closure, firing, and/or articulating of the end
effector, for example. An end effector can include a first jaw, a
second jaw, and one or more sensors configured to detect the
position of the first jaw relative to the second jaw. Referring now
to FIGS. 121-124, an end effector 10360 can comprise a first jaw,
or anvil, 10362 and a second jaw, or staple cartridge, 10364,
wherein the anvil 10362 is movable toward and away from the staple
cartridge 10364. Oftentimes, the end effector 10360 is inserted
through a trocar into a patient where the end effector 10360 may
not be readily visible even with the assistance of an endoscope. As
a result, the user of the surgical instrument may not be able to
readily assess the position of the anvil 10362 relative to the
second jaw 10364. To facilitate the use of the end effector, as
mentioned above, the end effector 10360 can include a sensor for
detecting the position of the anvil 10362. In various
circumstances, such a sensor can be configured to detect the gap
between the anvil 10362 and the staple cartridge 10364. Certain
sensors can be configured to detect the rotational position of the
anvil 10362 relative to the staple cartridge 10364. Sensors are
disclosed in U.S. patent application Ser. No. 13/800,025, entitled
STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which was filed on
Mar. 13, 2013, and U.S. patent application Ser. No. 13/800,067,
entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which was
filed on Mar. 13, 2013. The entire disclosures of U.S. patent
application Ser. No. 13/800,025, entitled STAPLE CARTRIDGE TISSUE
THICKNESS SENSOR SYSTEM, which was filed on Mar. 13, 2013, and U.S.
patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGE
TISSUE THICKNESS SENSOR SYSTEM, which was filed on Mar. 13, 2013,
are incorporated by reference herein. Regardless of the sensor, or
sensors, used, the position of the anvil 10362 can be communicated
to the user of the surgical instrument through a display. Such a
display can be located on the end effector 10360 and/or a shaft of
the surgical instrument, such as shaft 10340, for example. When the
display is located on the end effector, the display may be viewable
utilizing an endoscope, for example. In such instances, the display
may be positioned on the end effector such that it is not obscured
by the trocar which allowed the end effector to enter the surgical
site. Stated another way, the display can be located such that it
is distal with respect to the distal end of the trocar when in use.
When the display is located on the shaft, the display may be
positioned on the shaft such that it is not obscured by the trocar.
Stated another way, the display can be located such that it is
proximal with respect to the proximal end of the trocar when in
use. With reference to the embodiment depicted in FIGS. 121-124, a
display 10390 is located on the shaft 10340.
[0283] With continued reference to FIG. 121, the anvil 10362 of the
end effector 10360 is depicted in a fully-open position. In this
position of the anvil 10362, a firing member 10330 of the end
effector 10360 is in a proximal position and has not yet been
advanced distally. As will be discussed in greater detail below,
the firing member 10330 is advanced distally to move the anvil
10362 toward the staple cartridge 10364. The position of the firing
member 10330 illustrated in FIG. 121 can represent an unfired,
proximal-most position of the firing member 10300. When the anvil
10362 is in its fully-open position, referring primarily to FIG.
125, the anvil display 10390 may not be illuminated. As the reader
will appreciate, the anvil display 10390 can depict the position of
the anvil 10362 in one of several different positions. Anvil
display 10390 happens to be capable of depicting five potential
positions of the anvil 10362; however, other embodiments are
envisioned which can include an anvil display utilizing more than
five indicators or less than five indicators. As the anvil 10362 is
moved from its open position to its closed position, the display
10390 can sequentially depict the position of the anvil 10362
utilizing indicators 10391-10395. Indicator 10391 depicts the anvil
10362 in a slightly-closed position. Indicators 10392, 10393, and
10394 depict the anvil 10362 in partially closed positions.
Indicator 10395 depicts the anvil 10362 in a fully-closed, or
parallel, position. Upon comparing FIG. 121 with FIG. 122, the
reader will appreciate that the firing member 10330 has been
advanced distally to at least partially close the anvil 10362. When
the anvil 10362 is in the position depicted in FIG. 122, the anvil
position sensor can detect the new position of the anvil 10362 and
the indicator 10391 of the anvil display 10390 can be illuminated,
as illustrated in FIG. 126. Upon comparing FIG. 122 with FIG. 123,
the firing member 10330 has been advanced distally to further
close, although not completely close, the anvil 10362. When the
anvil 10362 is in the position depicted in FIG. 123, the anvil
position sensor can detect the new position of the anvil 10362 and
the indicator 10393 can be illuminated, as illustrated in FIG. 127.
Upon further comparing FIG. 122 and FIG. 123, the reader will
appreciate that the anvil 10362 has been rotated about 10 degrees,
for example, and that, if the anvil 10362 had been rotated only
about 5 degrees, for example, the indicator 10392 of the anvil
display 10390 would have been illuminated. Upon comparing FIG. 123
with FIG. 124, the firing member 10330 has been advanced distally
to completely close the anvil 10362. When the anvil 10362 is in the
position depicted in FIG. 124, the anvil position sensor can detect
the new position of the anvil 10362 and the indicator 10395 can be
illuminated, as illustrated in FIG. 128. Upon further comparing
FIG. 123 and FIG. 124, the reader will appreciate that the anvil
10362 has been rotated about 10 degrees, for example, and that, if
the anvil 10362 had been rotated only about 5 degrees, for example,
the indicator 10394 of the anvil display 10390 would have been
illuminated.
[0284] Further to the above, the end effector and/or the surgical
instrument can include a controller which can be configured to
control the anvil display 10390. For instance, when the end
effector includes the anvil display 10390, the controller can be
positioned within the end effector. When the shaft of the surgical
instrument includes the anvil display 10390, and/or any other
portion of the surgical instrument includes the anvil display
10390, the surgical instrument can include the controller. In other
instances, one of the end effector and the surgical instrument can
include the anvil display 10390 while the other of the end effector
and the surgical instrument can include the controller. In any
event, the anvil position sensor, or sensors, can be in signal
communication with the controller. The controller can be configured
to interpret one or more signals from the sensor, or sensors, to
determine the position of the anvil 10362. The controller can be in
communication with the anvil display 10390 in order to illuminate
the indicators 10391-10395 as outlined above. In various
circumstances, each indicator 10391-10395 can comprise a light
emitting diode, for example. In such circumstances, each light
emitting diode can be placed in electrical communication with an
output channel of a microprocessor of the controller such that the
controller can selectively illuminate a light emitting diode
independently of the other light emitting diodes. In various
instances, the controller can continuously evaluate the position of
the anvil 10362 based on data from the anvil sensor and, utilizing
this data, continuously update which indicator is illuminated. For
instance, when the anvil 10362 is being closed or opened, the
controller may track the position of the anvil 10362 and promptly
display this information to the user of the surgical instrument
through the indicators 10391-10395. Such instances may provide the
user with real-time, or nearly real-time, feedback as to the
position of the anvil 10362. In other instances, the controller may
wait to display the position of the anvil 10362 until after the
anvil 10362 has stopped moving, or at least substantially stopped
moving, for a certain period of time, for example. As the reader
will appreciate, the indicators 10391-10395 can represent discrete
positions of the anvil 10362; however, it is likely that the anvil
10362 may only momentarily pass through each of these discrete
positions when it is closed, for example. In various circumstances,
the controller may utilize an algorithm in order to decide which
indicator to illuminate. For instance, the controller can apply an
algorithm which determines which indicator more accurately
represents the position of the anvil 10362 even though the anvil
10362 may not be aligned with any of the discrete positions that
can be represented by the indicator display 10390. In various
circumstances, the controller can illuminate two adjacent
indicators in the indicator display 10390 when the anvil 10362 is
positioned intermediate the two discrete positions represented by
the two adjacent indicators.
[0285] In various instances, further to the above, the indicators
10391-10395 can each comprise a light emitting diode which emits
the same color light, or at least substantially the same color
light. In other instances, one or more of the indicators
10391-10395 can emit a color which is different than the other
indicators 10391-10395. For instance, indicator 10391 could be
configured to emit a yellow color while indicators 10392-10395 can
be configured to emit a green color, for example. As the reader
will appreciate, referring to FIG. 122, the tissue T positioned
between the anvil 10362 and the cartridge 10364 may not be
adequately clamped by the anvil 10362 when the anvil 10362 is in
the partially-closed position illustrated in FIG. 122 and, when the
indicator 10391 associated with this position of the anvil 10362 is
illuminated yellow, the user of the surgical instrument may be
reminded to take caution before moving the end effector 10360
and/or continuing the firing process. In some instances, one or
more of the indicators 10361-10365 can each be configured to emit
more than one color. For instance, each indicator 10361-10365 can
comprise a light emitting diode configured to emit a green color
and a red color. In such instances, the indicators 10361-10365 can
emit a green color when indicating the position of the anvil 10362
as outlined above or, alternatively, emit a red color when an error
exists with the end effector 10360 and/or the surgical
instrument.
[0286] As discussed above, an anvil of an end effector can be
movable relative to a staple cartridge between an open position and
a closed position and the surgical instrument system can be
configured to detect the movement of the anvil and communicate the
movement of the anvil to the user. That said, embodiments are
envisioned in which the staple cartridge is movable relative to the
anvil. In at least one such embodiment, the anvil may be fixed or
non-pivotable. When fixed or non-pivotable, the anvil may extend
rigidly from a portion of the end effector frame; however, that
portion of the end effector frame, the anvil extending therefrom,
and the staple cartridge may be articulatable relative to another
portion of the end effector or the shaft of the surgical
instrument. Whether or not the end effector is articulatable, in
such embodiments, the staple cartridge can be pivotable relative to
the anvil. The systems and methods described herein for detecting
the movement of the anvil can be adapted to detecting the movement
of the staple cartridge. Moreover, the systems and methods
described herein for displaying the movement of the anvil can be
adapted to displaying the movement of the staple cartridge.
[0287] In various instances, an operator may desire to retract the
drive member during a firing stroke. The surgical instrument
disclosed in Zemlok '763 employs a retraction assembly that
comprises a manually-driven mechanical interface with the drive
tube that is activated by ratcheting a retraction lever mounted on
the handle. Such arrangement purports to enable the clinician to
retract the firing rod and ultimately the loading unit drive member
should the power source become interrupted or the motor or control
system fail during firing. However, such retraction assembly can be
difficult to effectively operate due to the fact that the motor and
the motor gear box remained engaged during the ratcheting
(activation) process. Thus, the retraction assembly of that device
must be able to develop enough torque to rotate the gears in the
gear box and motor shaft to enable the drive tube to be manually
rotated. The generation of such forces may place extreme stress on
the retraction assembly components which may lead to catastrophic
failure of the retraction assembly. The surgical instruments 10
depicted in FIGS. 1-28 may be configured with unique and novel
retraction assembly arrangements which may avoid this problem and
others.
[0288] For example, the surgical instrument 10 may include a
retraction assembly 120 that includes a retraction chassis 124 that
has a top portion 126 and a bottom portion 128. In various forms,
the retraction assembly 120 interfaces mechanically with the drive
tube 102 via a drive gear 130 and a retraction gear 132. See FIG.
5. The drive gear 130 is non-rotatably attached to the drive tube
102 such that rotation of the drive gear 130 imparts rotation on
the drive tube 102. The drive gear 130 and the retraction gear 132
may comprise bevel gears or the like to permit intermeshing
engagement therebetween as shown in FIG. 5. The retraction gear 132
may be coupled to a first spindle 134 (FIGS. 4 and 5) which is
substantially perpendicular to the top and bottom portions 126 and
128 of the retraction chassis 124 and extends therebetween. The
spindle 134 may be supported for rotational travel about a spindle
axis "SA-SA" that is substantially perpendicular to the
longitudinal axis "LA-LA" of the surgical instrument 10. See FIG.
5. In various forms, the retraction gear 132 may have a first spur
gear 136 attached thereto. The first spur gear 136 interfaces with
a second spur gear 138 that is operably supported on a second
spindle 137 which is also disposed in a substantially perpendicular
manner between the top and bottom portions 126 and 128 of the
retraction chassis 124 and is rotatable around a second shaft axis
"SA'-SA'" defined thereby. The second spur gear 138 is supported
for meshing engagement with a third spur gear 140 which is disposed
on the first spindle 134. The third spur gear 140 is attached to a
first clutch portion 144 of a unidirectional clutch assembly 142.
The clutch assembly 142 further includes a second clutch portion
146 that is rotatably disposed on the first spindle 134 above the
first clutch portion 144. A spring or springs (not shown) may be
disposed between the first and second clutch portions 144 and 146
thereby maintaining the first and second clutch portions 144 and
146 in a raised "non-interlocking" orientation as illustrated in
FIG. 5.
[0289] It will be appreciated that as the drive tube 102 is
rotated, the drive gear 130 will impart rotation to the first,
second and third spur gears 136, 138, 140 as well as to the first
clutch portion 144 and the respective spindles 134, 137. Because
the second clutch portion 146 can rotate about the spindle 134 and
is biased out of engagement with the first clutch portion 144 by
the spring arrangement disposed therebetween (not shown), the
rotation of the first clutch portion 144 is not translated to the
second clutch portion 146. As can be seen in FIG. 5, the first and
second clutch portions 144 and 146 include a plurality of
interlocking teeth 148 that each have a flat interlocking surface
and a sloping slip surface. As will be discussed in further detail
below, the second clutch portion 146 may be biased into meshing
engagement with the first clutch portion 144 by the retraction
lever 150. The slip surfaces on the teeth 148 allow for the
interlocking surfaces to come in contact with each such that
rotation of the second clutch portion 146 causes the first clutch
portion 144 to rotate. Rotation of the first clutch portion 144
also causes all of the interfacing gears to rotate as well to
ultimately impart rotational motion to the drive tube 102 about the
longitudinal tool axis LA-LA.
[0290] Referring now to FIG. 6, the retraction lever 150 may
include an elongated handle portion 152 that includes a camming
portion 154. The camming portion 154 may include an opening which
may house a unidirectional needle clutch (not shown) which is
supported in mechanical cooperation with a fitting (not shown) that
may be attached to the first spindle 134 to enable the retraction
lever 150 to rotate about the first spindle 134. Zemlok '763
further describes an operation of such a unidirectional needle
clutch and fitting arrangement and was incorporated by reference
herein in its entirety. In various forms, the retraction lever 150
includes a one or more camming members 156 that each have a camming
surface 158 thereon. In a first orientation, the retraction lever
150 is disposed along a lever pocket 14 of the housing 12 as shown
in FIG. 1. The spring disposed between the first and second clutch
portions 144, 146 serves to bias the retraction lever 150 against
the top portion 126 of the retraction chassis 124. As can be seen
in FIG. 6, the camming members 156 are disposed within
corresponding cam slots or pockets 160 in the top portion 126 of
the retraction chassis 124. The retraction lever 150 is maintained
in a first orientation by a return spring 162 that is mounted
between the top portion 126 of the retraction chassis 124 and the
camming portion 154 of the retraction lever 150. The camming
members 156 and the cam slots 160 prevent further rotation of the
retraction lever 150.
[0291] In use, when the retraction lever 150 is moved out of the
lever pocket 14 (FIG. 1) in the housing 12, the camming members 156
interface with the corresponding cam slots 160 to bias the camming
portion 154 of the retraction lever 150 in a downward direction
against the biasing force of the spring(s) positioned between the
first and second clutch portions 144, 146. Such downward movement
compresses the spring(s) and pushes the first and second clutch
portions 144, 146 into interlocking engagement. Rotation of the
camming portion 154 in a counterclockwise direction actuates the
needle clutch which interfaces with the fitting and the first
spindle 134. Continual actuation of the retraction lever 150
rotates the clutch assembly 142 which in turn rotates the spur
gears 136, 138, 140 and the retraction and drive gears 132 and 130.
This in turn rotates drive tube 102 about the longitudinal tool
axis "LA-LA". Because the firing rod 104 is in threaded engagement
with the drive tube 102, rotation of the drive tube 102 in the
above-described manner results in the retraction (or proximal axial
travel) of the firing rod 104 into the drive tube 102.
[0292] In operation, the drive tube 102 may be configured to be
rotated in a direction that is opposite to the retraction direction
(e.g., in a clockwise direction, for example) about the
longitudinal tool axis" LA-LA" by the motor 100. Such rotation of
the drive tube 102 causes the firing rod 104 to move axially in the
distal direction "DD". This advancement of the firing rod 104 and
the drive member 60 of the loading unit 20 may be referred to
herein as a "firing" action. As can be seen in FIG. 5, for example,
a gear assembly 170 is employed to establish an amount of driving
torque required to drive the firing rod 104 in the distal direction
"DD" to actuate the loading unit 20. The gear assembly 170 may
include a gear box housing 172 that is coupled to the motor 100.
For example, the gear box housing 172 may be coupled to the motor
housing 101 by screws 103 or other mechanical fasteners and/or
fastener arrangements. The gear assembly 170 and motor 100 may be
collectively referred to as "drive unit", generally designated as
186.
[0293] The gear box housing 172 may be rotatably supported in a
motor retainer portion 190 that is integrally formed or otherwise
non-rotatably supported by the housing 12. Such arrangement permits
the drive unit 186 to rotate within the housing 12 about the
longitudinal tool axis "LA-LA", but prevents axial movement thereof
within the housing 12. The motor 100 may, for example, be powered
by the power source 200 of the type described in further detail in
Zemlok '763 and/or the power system 2000 (FIG. 129).
[0294] To facilitate supply of electrical current to the drive unit
180 and, more particularly, to the motor 100, a unique contact
arrangement 210 may be employed. For example, the contact
arrangement 210 may include an annular negative motor contact 212
and an annular positive motor contact 114 supported on the motor
housing 101 as can be seen in FIG. 4. A fixed negative contact 216
may be supported within the housing 12 for sliding contact with the
negative motor contact 112. Similarly a fixed positive contact 218
may be supported for sliding contact with the positive motor
contact 214 as the drive unit 180 rotates within the housing 12.
The fixed negative and positive contacts 216, 218 may comprise
flexible spring-like contacts to facilitate assembly and adjustment
of the drive unit 186 within the housing 12. The fixed negative
contact 216 may be electrically coupled to the power source 200 by
a negative lead 220 and the fixed positive contact 218 may be
electrically coupled to the power source 200 by a positive lead
222. Such contact arrangement enables electrical power to be
supplied from the power source 200 to the motor 100 while
facilitating rotation of the drive unit 186 within the handle
housing about the longitudinal tool axis "LA-LA".
[0295] Referring to FIG. 5, the gear assembly 170 may comprise a
planetary gear arrangement that is operably coupled to the motor
shaft 107. In one arrangement for example, a ring gear 173 may be
formed on the inner surface of the gear box housing 172. A primary
sun gear 171 may be coupled to the motor shaft 107. The primary sun
gear 171 may be supported in meshing engagement with a plurality of
first planetary gears 175 that are supported on a first planetary
gear carrier 174 such that they are also in meshing engagement with
the ring gear 173. A first sun gear 176 may be formed on or
otherwise attached to the first planetary gear carrier 174 and may
be supported in meshing engagement with a plurality of second
planetary gears 178 that are supported on a second planetary gear
carrier 177. The second planetary gears 178 may also be supported
in meshing engagement with the ring gear 173. A second sun gear 179
may be formed on or otherwise attached to the second planetary gear
carrier 177 and may be supported in meshing engagement with a
plurality of third planetary gears 181. The third planetary gears
181 may be supported on a third planetary gear carrier 180 in
meshing engagement with the ring gear 173. A third sun gear 183 may
be formed on or is otherwise attached to the third planetary gear
carrier 180 and is in meshing engagement with a plurality of fourth
planetary gears 187 that may be attached to an output shaft unit
184 that is rotatably supported within the gear box housing 172 by
a bearing 185. The fourth planetary gears 187 may also be supported
in meshing engagement with the ring gear 173.
[0296] FIG. 7 illustrates one arrangement for rotatably supporting
the drive unit 186 within the housing 12. As can be seen in that
Figure, a motor mount boss 192 of the motor retainer 190 may
include a gear box housing segment 196 that is rotatably supported
therein. In one arrangement, for example, the gear assembly 170 is
rotatably supported in the gear box housing segment 196 by bearing
185. Similarly, the motor 100 is rotatably supported within a motor
mount housing portion 13 by a bearing 198. Other methods of
rotatably supporting the drive unit 186 within the housing 12 may
also be employed.
[0297] The output shaft unit 184 may be operably coupled to a
clutch 230 (FIG. 5) of the type and construction disclosed in
Zemlok '763 which has been herein incorporated by reference in its
entirety. Further details regarding the construction and operation
of such clutch 230 may be obtained from that publication. In an
alternative embodiment, however, the clutch 230 may be replaced
with a shaft-to-shaft coupler or sleeve arrangement that serves to
facilitate the coupling of the output shaft unit 184 directly to
the drive tube 102.
[0298] When the axially movable drive beam of the surgical
instrument disclosed in Zemlok '763 became jammed or power was lost
to the instrument, the user had to employ the retraction assembly
to retract the drive beam back to a starting position to facilitate
removal of the loading unit. However, effective retraction was
difficult because the retraction system had to generate a
sufficient amount of torque necessary to reverse the plurality of
gear arrangements in the gear assembly. Thus, such retraction
system could be extremely difficult to operate effectively.
[0299] At least one surgical instrument embodiment disclosed herein
employs a unique and novel releasable drive unit locking system,
generally designated as 240, to address such problem. As will be
discussed in further detail below, for example, when the releasable
drive unit locking system 240 is in a "locked" position, the drive
unit 186 is prevented from rotating within the handle housing 12.
The drive unit 186 is retained in the locked position when the
surgical instrument is "fired" to facilitate transfer of the motor
torque from the motor 100 through the gear assembly 170 and
ultimately to the drive tube 102. When it is desirable to activate
the retraction assembly 120, the drive unit locking system 240 is
moved to an "unlocked" position to enable the drive unit 186 to
freely rotate within the housing 12 to thereby avoid the need to
generate sufficient retraction torque to reverse the gear
arrangements in the gear assembly 170. The gear assembly 170 can
remain operably coupled between the motor 100 and the drive tube
102 during operation of the retraction assembly 120. In such
embodiments, though the gear assembly 170 remains operably coupled
to the motor 100 and the drive tube 102, free rotation of the drive
unit 186 can reduce the torque required to drive the gear assembly
170 as the gear arrangements reverse to retract the drive tube 102.
Such a reduction in required torque can improve the effectiveness
of the retraction system.
[0300] As can be seen in FIG. 8 for example, the third spur gear
140 of the retraction assembly 120 may include an unlocking cam 141
that is configured to actuate a locking pawl assembly 250 of the
drive unit locking system 240. One form of locking pawl assembly
250 is illustrated in FIGS. 9-11. As can be seen in FIG. 10 for
example, the locking pawl assembly 250 may include a pawl member
252 that has a locking notch 254 formed therein. The locking notch
254 is sized to permit a series of spaced, first lock wedges 256
formed around the outer circumference of the gear box housing 172
to freely pass therethrough. See, e.g., FIGS. 12 and 13. A pawl
lock wedge 258 is formed on the locking pawl 252 for locking
engagement with any of the first lock wedges 256 as will be
discussed in further detail below. As can also be seen in FIGS.
8-11, the locking pawl assembly 250 may further include a pawl
guide rod 260 that is configured to be slidably received within a
passage 194 in the motor mount boss 192. A pawl spring 262 is
journaled on the pawl guide rod 260 and is positioned between the
pawl member 252 and the motor mount boss 192 to bias a cam
engagement portion 264 of the pawl member 252 into engagement with
the third spur gear 140.
[0301] One method of operating the retraction assembly 120 and the
drive unit locking system 240 will now be described with reference
to FIGS. 8, 13 and 14. FIG. 13 illustrates the drive unit locking
system 240 in the locked position. As can be seen in that Figure,
the pawl member 252 is biased into the distal locking position by
the pawl spring 262. When in that locked position, the pawl lock
wedge 258 on the pawl member 252 is in locking engagement with a
corresponding one of the first locking wedges 256 on the gear box
housing 172. When in that position, the retraction assembly 120 has
not been activated and the gear assembly 170 is prevented from
rotating within the housing 12. Operation of the motor 100 by
depressing the main power switch 80 (FIG. 1) results in the
rotation of the drive tube 102 and ultimately the axial advancement
of the firing rod 104 which drives the drive beam 60 distally
through the loading unit 20.
[0302] If, for example, the drive beam 60 becomes jammed in the
tissue clamped in the loading unit 20 or power is lost to the motor
100 or for some other reason the motor 100 is unable to reverse the
rotation of the drive tube 102 to ultimately retract the firing rod
104, the clinician may employ the retraction assembly 120 to
manually retract the firing rod 104 and drive beam 60. FIG. 8
illustrates the retraction assembly 120 in the unactuated position
(e.g., when the drive unit locking system 240 is in the locked
position). To commence the manual retraction process, the clinician
pulls the retraction lever 150 out of the lever pocket 14 in the
handle housing 12 (in the "R" direction--see FIG. 6). Movement of
the retraction lever 150 in the "R" direction results in the
rotation of the camming portion 154 of the retraction lever 150
within the retraction chassis 124. Such initial rotation of the
retraction lever 150 in the "R" direction causes the unlocking cam
141 to engage the cam engagement portion 264 of the pawl member 252
to bias the pawl member 252 to the unlocked position thereby
enabling the drive unit 186 to freely rotate within the handle
housing 12. The cam slots 160 in the retraction chassis are located
and have a sufficient length to facilitate this rotational travel
of the camming portion 154 of the retraction lever 150 without
initially disengaging the clutch assembly 142. Thus, the cam slots
160 may be longer than the cam slots located in prior retraction
chassis arrangements to facilitate the unlocking of the drive unit
assembly 186 prior to applying the actuation motions which result
in the rotation of the drive tube 102. For example, in at least one
arrangement, the cam slots 160 may be elongated to facilitate
rotation of the retraction lever 150 approximately fifteen degrees.
As the clinician continues to rotate the retraction lever 150 in
the "R" direction, the cam engagement portion 264 will ride along
the outer circumference of the unlocking cam 141 on the third spur
gear 140. Continued rotation of the retraction lever 150 in the "R"
direction results in the engagement of the camming members 156 on
the camming portion 154 with the ends of their respective cam slots
160 to bias the camming portion 154 in the downward direction. This
downward movement compresses the spring(s) positioned between the
first and second clutch portions 144 and 146 to bring the teeth 148
thereon into meshing engagement with each other. Continued rotation
of the camming portion 154 in a counterclockwise direction may
actuate the needle clutch which interfaces with the fitting and the
first spindle. Continual actuation of the retraction lever 150
rotates the clutch assembly 142 which in turn rotates the spur
gears 136, 138, 140 and the retraction and drive gears 132 and 130.
This in turn rotates drive tube 102 and retracts the firing rod
104.
[0303] The retraction lever 150 can be actuated for a predetermined
amount of travel until a portion of the retraction lever 150 abuts
a portion of the housing 12. Thereafter, the retraction lever 150
is returned to its first position by the return spring 162. This
action raises the camming portion 152 allowing the second clutch
portion 146 to also move upward and disengage the first clutch
portion 144. The needle clutch may release the fitting to thereby
allow the retraction lever 150 to return to the first position
without affecting the movement of the drive tube 102. Once the
retraction lever 150 is returned to the first position, the drive
unit 186 is once again retained in a locked position. The
ratcheting or rotation of the retraction lever 150 may be repeated
over and over until the firing rod 104 has been returned to a
desired position.
[0304] Because the gear box housing 172 is free to rotate during
the application of this rotational motion, the amount of torque
required to rotate the drive tube 102 and the gears within the gear
assembly 170 is greatly reduced as compared to the torque required
to operate prior retraction assemblies. Such arrangement also
advantageously serves to prevent the transfer of the torque forces
generated by the retraction assembly to the motor shaft 107 while
the gear assembly 170 remains drivingly coupled to the motor shaft
107. In other words, the gear assembly 170 can remain drivingly
coupled between the motor shaft 107 and the drive tube 102 during
operation of the retraction assembly 120. Such arrangement differs
from retraction arrangements disclosed in, for example, U.S. Pat.
No. 7,959,050, which is incorporated by reference in its entirety
herein, but which result in the physical decoupling or physical
interruption of portions of the transmission during activation of
the retraction system.
[0305] FIGS. 15-18 illustrate another surgical instrument 310 that
is substantially similar to surgical instrument 10 described above,
except for the differences discussed below. As can be seen in FIG.
16, the instrument 310 includes a gear assembly 470 that comprises
a gear box housing 472 that may be coupled to the motor 100 in the
manner described above, for example. The gear box assembly 470 and
motor 100 may be collectively referred to as "drive unit",
generally designated as 486. The gear assembly 470 may be identical
to gear assembly 170 described above except for the differences
discussed below.
[0306] In at least one arrangement, the gear box housing 472 may be
non-rotatably supported in or integrally formed with a motor
retainer portion 190 that is integrally formed or otherwise
non-rotatably attached within the housing 12 in the various manners
discussed herein. Because the drive unit 486 does not rotate in
this arrangement, it may be directly wired to the power source. For
example, the motor 100 may be powered in the manner described in
Zemlok '763 or other suitable manners. As can be seen in FIG. 16,
the gear assembly 470 may comprise a planetary gear arrangement
that is operably coupled to the motor shaft 107. In one arrangement
for example, a fixed ring gear 473 may be formed on the inner
surface of the gear box housing 472. A primary sun gear 471 may be
attached to the motor shaft 107. The primary sun gear 471 may be
supported in meshing engagement with a plurality of first planetary
gears 475 that are supported on a first planetary gear carrier 474.
The first planetary gears 475 may also be in meshing engagement
with the fixed ring gear 473. A first sun gear 476 may be formed on
the first planetary gear carrier 474 and be in meshing engagement
with a plurality of second planetary gears 478 that are supported
on a second planetary gear carrier 477. The second planetary gears
478 may also be supported in meshing engagement with the fixed ring
gear 473. A second sun gear 479 may be formed on or attached to the
second planetary gear carrier 477 and be supported in meshing
engagement with a plurality of third planetary gears 481 supported
on a third planetary gear carrier 480. The third planetary gears
481 are in meshing engagement with the fixed ring gear 473. A third
sun gear 483 may be formed on or otherwise be attached to the third
planetary gear carrier 480. The third sun gear 483 may be supported
in meshing engagement with a plurality of fourth planetary gears
487 that are attached to an output shaft unit 484 that is rotatably
supported within the gear box housing 472 by a bearing 185. The
plurality of fourth planetary gears 487 may be in meshing
engagement with a lockable ring gear 485 that is rotatably mounted
in the gear box housing 472. The gears 471, 473, 475, 476, 478,
479, 481 and 483 may be collectively referred to herein as gear
train assembly 460.
[0307] The lockable ring gear 485 may be rotatably mounted within
an annular cavity 490 in the motor retainer portion 190 (FIG. 16).
Cavity 490 is sized to permit the free rotation of the lockable
ring gear 485 therein about the longitudinal tool axis "LA-LA". The
lockable ring gear 485 may be installed in the annular passage 490
and then retained in position by a plug member 492 that is pressed
into or otherwise retained in the annular passage 490.
[0308] The surgical instrument 310 may further include a drive unit
locking system 540 that includes a movable shift ring assembly 542.
In at least one form, the shift ring assembly 542 may include, for
example, a shift ring 543 that has at least one, and preferably a
plurality of, locking members in the form of, for example, pins
544. Pins 544 protrude from the shift ring 543 and are configured
for selective locking engagement with the lockable ring gear 485.
Each of the locking pins 544 may be slidably received within a
corresponding passage 546 in the plug member 492. The shift ring
542 is supported for axial movement by a reversing link 550 that is
attached to a clutch clamp 560. As can be seen in FIG. 15, the
clutch clamp 560 may comprise a spring clamp that is clamped about
a portion of the outer circumference of the third spur gear 140.
The clutch clamp 560 may have a lug 562 thereon that is attached to
a shifter rod 564. The shifter rod 564 may be somewhat flexible and
be pivotally coupled to the shift ring 542. During normal use
(i.e., when the motor 100 is driving the firing rod 104), the
locking pins 544 are in locking engagement with the lockable ring
gear 475 to prevent the lockable ring gear 475 from rotating such
that the rotational torque is transferred to the output shaft unit
484 and ultimately to the drive tube 102.
[0309] When the clinician desires to employ the retraction assembly
120 to retract the firing rod 104, the retraction lever 150 is
rotated from the starting position shown in FIG. 15 in "R"
direction. As the retraction lever 150 is rotated, the clutch clamp
560 rotates with the third spur gear 140 to thereby cause the
shifter rod 564 to move the shift ring 542 in the distal direction
"DD". As the shift ring 542 moves in the distal direction "DD", the
locking pins 544 move out of locking engagement with the lockable
ring gear 485 to permit the lockable ring gear 485 to rotate
relative to the gear box housing 472. The clinician continues to
ratchet the retraction lever 150 to the end position shown in FIG.
18. In at least one arrangement for example, the retraction lever
150 need only be rotated approximately fifteen degrees to disengage
the locking pins 544 from the lockable ring gear 485. After the
clinician releases the retraction lever 150, the return spring 162
will return the retraction lever 150 to the starting position and
the clinician can repeat the procedure until the firing rod 104 is
retracted to a desired position. Because the lockable ring gear 485
is free to rotate within the bearing housing 472, rotation of the
drive tube 102 and the output shaft unit 484 will not be resisted
by the other gear arrangements in the gear assembly 470. As such,
the amount of ratcheting torque required to retract the firing rod
104 is reduced when compared to retraction arrangements that remain
operably engaged with the gear arrangements in the gear assembly
during the retraction process. Furthermore, though the required
torque is reduced, the firing rod 104 can remain operably engaged
with the gear assembly 470. In other words, the firing rod 104 can
remain operably coupled to the motor 100. When the shift ring 542
contacts the bearing 185 in the motor mount boss 192, the locking
pins 544 lockingly engage the lockable ring gear 485. The clutch
clamp 560 may be configured to slip relative to the third spur gear
140 after the shift ring contacts the bearing 185 or other portion
of motor mounting boss 192. Thus, the drive unit locking system 540
serves to facilitate rotation of at least a portion of the drive
unit within the handle housing during the application of retraction
motions to the drive tube 102 to reduce the amount of retraction
torque required to retract the firing rod 104.
[0310] The surgical instrument 610 in FIG. 19 is substantially
identical to the surgical instrument 310 except that the clutch
clamp 560 is attached to the third spur gear 140 in such a way as
to eliminate the reversing link 550 employed in the surgical
instrument 310. As can be seen in FIG. 18 for example, the shifter
rod 564 is directly connected to the shift ring 542. Ratcheting of
the retraction lever 150 in the above-mentioned manner results in
the movement of the shift ring 542 and the engagement and
disengagement of the locking pins 544 with the lockable ring gear
485.
[0311] FIGS. 20 and 21 illustrates another surgical instrument 610'
that is substantially identical to surgical instrument 610 except
for the following differences. In this arrangement, for example, at
least two "leaf-type" lock springs 620 and ring gear lock members
622 are supported on the gear box housing 472' of the gear assembly
470'. As can be seen in FIG. 20, each lock spring 620 and
corresponding lock member 622 is supported in a slot 624 in the
gear box housing 472'. In this arrangement, the locking pins 544'
that are attached to the shift ring 542 are configured to contact
and depress the corresponding locking spring 620 inwardly to press
the corresponding ring gear lock member 622 into locking engagement
with the lockable ring gear 485. When in that position (shown in
FIG. 20), the lockable ring gear 485 is prevented from rotating in
relative to the gear box housing 472'. When the shifter rod 564
pulls the shift ring 542 in the distal direction "DD", the locking
pins 544' disengage their corresponding locking spring 620 which
enables the spring 620 to flex to a starting position to enable the
ring gear lock members 622 to disengage the lockable ring gear 485
to permit it to rotate relative to the gear box housing 472'. Thus,
when the retraction assembly 120 is activated, the lockable ring
gear 485 is free to rotate relative to the gear box housing 472' to
thereby reduce the amount of retraction torque needed to cause the
firing rod 104 to be retracted in the proximal direction "PD".
[0312] FIGS. 22-24 illustrate another retraction assembly
arrangement for selectively manually retracting a distal portion of
the firing rod of a surgical instrument 710 should the distal
portion of the firing rod or other component of the surgical
instrument to which it is operably attached become jammed during
operation or operational power for advancing the firing rod
assembly is interrupted. Except for the differences discussed
below, the surgical instrument 710 may be similar in design and
operation to the surgical instruments described above and/or
disclosed in Zemlok '763, which has been incorporated by reference
herein in its entirety.
[0313] As can be seen in FIGS. 22-24, the surgical instrument 710
includes a housing 712 that operably supports a firing rod assembly
720. The housing 712 may, for example, operably support a motor and
gear assembly (not shown) for applying rotary motions to a drive
tube which may result in the axial movement of the firing rod
assembly 720 in the various manners described herein. In at least
one arrangement, the firing rod assembly 720 may include a proximal
firing member or rod portion 722 that operably interfaces with the
drive tube in the various manners disclosed herein. In still other
surgical instrument arrangements, the proximal firing rod portion
722 may operably interface with other drive arrangements and
systems that are configured to apply axial motions to the proximal
firing rod portion 722.
[0314] As can be further seen in FIGS. 22-24, the firing rod
assembly 720 may further include a distal firing member or rod
portion 724 that is operably coupled to a proximal end of the
axially movable drive beam 60 of a loading unit 20 coupled thereto
in the various manners described herein. A retraction assembly 730
in the form of a retraction linkage assembly 732 may be pivotally
coupled between the proximal firing rod portion 722 and the distal
firing rod portion 724. In the illustrated arrangement, the
retraction linkage assembly 732 includes an actuator link 734 that
has a link handle portion 736 that is pinned to the proximal firing
rod portion 722. The retraction linkage assembly 732 further
includes a distal retraction link 738 that is pinned to the
actuator link 734 and the distal firing rod portion 724 as shown.
In the illustrated embodiment, the housing 712 includes a
distally-extending articulation housing portion 714 that may also
include a distally-extending, shaft housing segment 716. The shaft
housing segment 716 may serve to axially support the retraction
linkage assembly 732 as it axially moves in the distal and proximal
directions in response to the axial movement of the firing rod
assembly 720. To facilitate axial movement of the retraction
linkage assembly 732 relative to the shaft housing segment 716, the
actuator link 734 extends out through a slot 718 formed in the
shaft housing segment 716 as shown.
[0315] FIG. 22 illustrates the position of the firing rod assembly
720 and the retraction assembly 730 prior to firing. FIG. 23
illustrates the position of the firing rod assembly 720 and the
retraction assembly 730 after being fired in the distal direction
"DD". If during the firing process, the clinician desires to
retract the drive beam 60 back to a starting position, the
clinician can simply grasp the link handle portion 736 of the
actuator link 734 and pivot it in the "R" direction as shown in
FIG. 24 which draws the distal firing rod portion 724 and the drive
beam 60 in the proximal "PD" direction. As illustrated in FIGS. 22
and 23, during firing, the proximal end 725 of the distal firing
rod portion 724 may be normally axially spaced from the distal end
735 of the proximal firing rod portion 734 a distance designated as
"RD". The distance "RD" may remain, for example, unchanged during
firing and normal retraction of the firing rod assembly 720 by the
drive unit. However, when the clinician activates the retraction
assembly, the distance between the proximal end 725 of the distal
firing rod portion 724 and the distal end 735 of the proximal
firing rod portion 734 (distance "RD'") will be less than distance
"RD". In addition, as can be seen in FIG. 22, the distance between
the starting position of the distal working head 62 of the drive
beam 60 and the ending position of the distal working head 62
(i.e., after a complete firing stroke) is represented as distance
"FD". If desired, the distance "RD" may be sufficiently large
enough to enable the distal firing rod portion 724 to be
sufficiently retracted (i.e., moved closer to the distal end 735 of
the proximal firing rod portion 722) to return the working head 62
from the ending position back to its starting position. Stated
another way, the distal firing rod portion 724 may be retracted a
retraction distance that is at least equal to or greater than the
firing distance "FD". In such arrangement, for example, if the
working head 65 becomes jammed or otherwise stopped in its ending
position, activation of the retraction assembly can fully retract
the drive beam 60 to bring the distal working head 62 to its
starting position wherein the distal working head 62 can permit the
anvil 22 to pivot open and release the tissue.
[0316] FIGS. 25-28 illustrate an alternative firing rod assembly
720' that may be selectively manually retractable. The firing rod
assembly 720' as shown includes a proximal firing rod portion 722'
that may operably interface with the drive tube in the various
manners disclosed herein. In still other surgical instrument
arrangements, the proximal firing rod portion 722' may operably
interface with other drive arrangements and systems configured to
apply control motions to the proximal firing rod portion 722'. The
firing rod assembly 720' may further include distal firing rod
portion 724' that is at least partially hollow and operably coupled
to the end of the axially movable drive beam 60 of a loading unit
20 coupled thereto in the various manners described herein. For
example, the distal firing rod portion 724' may have a passage 725
therein that is sized to enable the distal firing rod portion 724'
to axially slide on the proximal firing rod portion 722' a
retraction distance "RDD". The retraction distance may be equal to
or greater than the firing distance "FD" to enable a retraction
assembly 730' to retract the drive beam 60 a sufficient distance so
as to move the working head 62 thereof from the ending position
"EP" to the starting position "SP". See FIG. 25. The retraction
assembly 730' may comprise a retraction latch 732'. The retraction
latch 732' may include a latch handle 735 that is movable between a
latched position (FIGS. 25 and 26) and an unlatched position (FIGS.
27 and 28). When in the latched position, the retraction latch 732'
affixes the distal firing rod portion 724' such that it is
prevented from axial sliding over the proximal firing rod portion
722' and the distal firing rod portion 724'. When in that
orientation, the proximal firing rod portion 722' essentially moves
as a unit. Thus, when in the latched orientation, the firing rod
assembly 720' may be fired in the distal direction "DD" to its
ending position "EP" as shown in FIG. 26. Should the drive beam 60
become jammed or power be interrupted or lost to the instrument
during the firing stroke (or for other reasons), the clinician can
simply move the retraction latch handle 735 to the unlatched
position (FIG. 27) and then manually pull the retraction latch 732'
in the proximal direction "PD" as shown in FIG. 28.
[0317] The various retraction systems and arrangements disclosed
herein may address certain shortcomings commonly encountered by
prior retraction arrangements used to retract motor-powered drive
members employed by surgical end effectors. For example, various
retraction arrangements disclosed herein may facilitate the manual
application of retraction motions to the drive member and/or
associated drive arrangements without encountering resistance
normally provided by the gear/transmission arrangements associated
with the motor, while enabling the gearing/transmission
arrangements to remain "drivingly" or physically coupled to the
motor.
[0318] Thus, at least one example comprises a surgical instrument
that may include a firing member assembly that may comprise a
portion that is supported for selective axial movement in a distal
direction and a proximal direction. The instrument may further
include a drive unit that comprises a motor that includes a motor
shaft. A gear assembly may be drivingly coupled to the motor shaft
and include an output shaft assembly that is configured to
interface with the firing member assembly such that when the motor
shaft is rotated in a first rotary direction, the portion of the
firing member assembly is axially driven in the distal direction
and when the motor shaft is rotated in a second rotary direction,
the portion of the firing member is axially driven in the proximal
direction. The surgical instrument may further comprise a
retraction assembly that interfaces with the firing member assembly
for manually applying other rotary motions to the firing member
assembly in the second rotary direction when the motor is
deactivated. The surgical instrument may further comprise locking
means that interfaces with the retraction assembly and the drive
unit for preventing transfer of the other rotary motions to the
motor shaft while the gear assembly remains drivingly coupled to
the motor shaft.
[0319] In accordance with yet another example, the surgical
instrument may comprise a drive unit for generating firing and
retraction motions. The instrument may further comprise a surgical
end effector that is configured to perform at least one surgical
function in response to an application of at least one of the
firing and retraction motions thereto. The surgical instrument may
further comprise a firing member assembly that may include a
proximal firing member portion that operably interfaces with the
drive unit and is configured to operably receive rotary actuation
motions therefrom. The firing member assembly may further comprise
a distal firing member portion that is supported distal to the
proximal firing member portion and is configured to transmit the
firing and retraction motions to the surgical end effector. A
retraction assembly may be operably coupled to the proximal firing
member portion and the distal firing member portion. The retraction
assembly may be selectively movable between an unactuated position
wherein the retraction assembly is configured to transfer the
firing and retraction motions from the proximal firing member
portion to the distal firing member portion and an actuated
position wherein the distal firing member portion is axially moved
relative to the proximal firing member portion.
[0320] Another surgical instrument example may comprise a handle
housing that includes an elongated shaft assembly that is operably
coupled thereto. The elongated shaft assembly may support an
axially movable firing rod therein. A loading unit may be operably
coupled to the elongated shaft and be configured to interface with
the firing rod. A drive tube may be rotatably supported within the
handle housing and operably interface with the firing rod. The
surgical instrument may further comprise a motor that has a motor
shaft. The motor may be operably supported within the handle
housing and be operably coupled to a power source. A gear assembly
may be drivingly coupled to the motor shaft and include an output
shaft assembly that is configured to interface with the drive tube
such that when the motor shaft is rotated in the first rotary
direction, the drive tube drives the firing rod in a distal
direction and when the motor shaft is rotated in a second rotary
direction, the drive tube drives the firing rod in a proximal
direction. A retraction assembly may interface with the drive tube
for manually applying other rotary motions thereto in the second
rotary direction when the motor is deactivated. A locking means may
interface with the retraction assembly and the gear assembly for
preventing transfer of the other rotary motions to the motor shaft
while the gear assembly remains drivingly coupled to the motor
shaft.
[0321] Referring again to FIGS. 1-3, in various embodiments, the
motor 100 of the surgical instrument 10 can be operably coupled to
a firing element, such as firing element 60, and can drive the
firing element 60 through the end effector or DLU 20 during a
firing stroke. For example, the firing element 60 can cut tissue
and/or fire staples into tissue during the firing stroke. A battery
can supply current to the motor 100, for example, and the current
supplied to the motor 100 can relate to the torque generated by the
motor 100. Furthermore, the torque generated by the motor 100 can
relate to the firing force exerted by the firing element 60. The
voltage across the motor can relate to the angular velocity of the
motor 100, for example, which can relate to the speed of the firing
element 60. Referring now to FIG. 63, the motor can define a
torque-voltage curve 5802. In various embodiments, the
torque-voltage curve 5802 can have a maximum torque T.sub.1 at
optimized voltage V. At voltages greater than and/or less than the
optimized voltage V, for example, the torque generated by the motor
can be less than the maximum torque T.sub.1. For example, at a
voltage of 1/2V, the torque-voltage curve 5802 can have a torque
T.sub.2, which can be less than T.sub.1, for example.
[0322] In various embodiments, a control system in signal
communication with the motor can supply current from the battery to
the motor. In some embodiments, the control system can include
speed management control, which can control the speed of the firing
element, for example. The control system can include a variable
resistance circuit and/or a voltage regulation circuit, for
example, which can control the current supplied to and/or the
voltage across the motor. In such embodiments, the control system
can control the torque and/or the angular velocity of the motor,
and thus, the firing force and/or the speed of the firing element
coupled to the motor. For example, a voltage regulation circuit can
regulate the voltage across the motor to affect the speed of the
firing element. Referring to FIG. 63, if the voltage regulation
circuit reduces the voltage from the ideal voltage V to 1/2V, for
example, the torque can be reduced to T.sub.2, which can be less
than the maximum torque T.sub.1, and the speed can be adjusted to
speed S.sub.2, for example.
[0323] In various embodiments, the control system can include a
pulse width modulation circuit, and the control system can supply
pulses of current to the motor. Referring primarily to FIGS.
64(a)-65(b), the current can be pulsed at a constant voltage. In
various embodiments, the duty cycle of the pulses, i.e., the
duration of the pulses per interval or period, can affect the
velocity of a firing element 5804. When the duty cycle is higher
(FIG. 64(a)), each pulse can be a longer portion of the interval,
and, as a result, the motor can drive the firing element 5804 at a
the faster speed S.sub.1, for example. When the duty cycle is lower
(FIG. 64(b)), each pulse can be a shorter portion of the interval,
and, as a result, the motor can drive the firing element 5804 at
the slower speed S.sub.3, for example. In various embodiments, the
pulse width modulation circuit can provide current pulses to the
motor at the optimized voltage V (FIG. 63) of the motor. In such
embodiments, the speed of the firing element 5804 can be controlled
without reducing the torque generated by the motor. For example,
the motor can operate at the optimized voltage V, to generate the
maximum torque T.sub.1, for example, and the firing element 5804
can be driven through the end effector at a reduced speed, such as
speed S.sub.3, for example, and/or any suitable speed by altering
the width of the voltages pulses.
[0324] In various embodiments, the battery can have a volt-ampere
limit or power threshold. In other words, the battery can supply a
limited amount of energy per unit time. The power threshold of the
battery can be related to the battery and/or circuit design. For
example, thermal limits on the battery and/or the circuit, such as
heat capacity and/or wire insulation, for example, can affect the
power threshold. Furthermore, the power threshold of the battery
can limit the amount of current supplied to the motor. In various
embodiments, a motor utilizing speed management control, such as
pulse width modulation, for example, may not require the maximum
volt-amperes of the battery. For example, when the battery supplies
current pulses at the maximum or optimized voltage to drive the
firing element at the desired speed and maximum or optimized
torque, surplus current may not be utilized to drive the firing
element. In such embodiments, the surplus current can be used to
produce additional torque. Referring to FIGS. 66(a)-66(c), a motor
can include an additional or secondary set of coils, for example,
and the surplus current can be selectively directed to the
additional set of coils to generate additional torque. In such
embodiments, the motor can produce more torque at lower speeds, for
example. In various embodiments, the control system can maximize
the surplus current supplied to the secondary set of coils based on
the volt-ampere limit of the battery, for example. Furthermore, in
certain embodiments, the control system can optimize the torque
generated by the motor during at least a portion of the firing
stroke.
[0325] Referring still to FIGS. 66(a)-66(c), a battery 6002 can
selectively supply current to a motor 6004. The motor 6004 can
include a primary set of coils 6006, and a secondary set of coils
6008, for example. In various embodiments, a control system 6020 in
signal communication with the motor 6004 can selectively direct
current to the primary set of coils 6006 and/or the secondary set
of coils 6008. For example, the control system 6020 can supply
current to the primary set of coils 6006 during a first operating
state, and can supply current to the primary set of coils 6006 and
the secondary set of coils 6008 during a second operating state,
for example. In various embodiments, a switch, such as switch 6010,
for example, can move between an open position and a closed
position to selectively supply current to the secondary set of
coils 6008, for example. In various embodiments, the sets of coils
6006, 6008 can be separately activatable. Furthermore, the control
system 6020 can include a pulse width modulation circuit 6022, and
the battery 6002 can supply current pulses to at least one of the
sets of coils 6006, 6008, for example. In various embodiments, the
primary set of coils 6006 can be coupled to a first circuit 6030
(FIG. 66(a)), and the second set of coils can be coupled to a
second circuit 6032 (FIG. 66(a)) that is independent of the first
circuit 6030. In other embodiments, the primary and secondary set
of coils 6006, 6008 can be arranged in parallel (FIG. 66(b)) or in
series (FIG. 66(c)), for example. In certain embodiments, the motor
6004 can include at least one additional set of primary coils
and/or at least one additional set of secondary coils, for
example.
[0326] In various embodiments, the motor can generate a first
amount of torque during the first operating state and a second
amount of torque during the second operating state. The second
amount of torque can be greater than the first amount of torque,
for example. Furthermore, the additional torque generated by the
secondary set of coils 6006 during the second operating state may
prevent and/or limit lock-out of the firing element during a firing
stroke. For example, referring to FIG. 67, the motor can drive the
firing element distally during the first operating state and can
drive the firing element proximally during the second operating
state. In various embodiments, the motor can generate greater
torque when retracting the firing element than when advancing the
firing element. In such embodiments, retraction of the firing
element may be improved. If the firing element becomes jammed,
e.g., the tissue is too thick and/or tough for the firing element
to cut and/or staple, the additional torque may be utilized to
retract the firing element, for example. Referring still to FIG.
66, the torque generated by the motor can be gradually increased
during a "soft" start phase 5902 of the firing stroke, and/or can
be gradually decreased during a "soft" stop 5904, 5906 phase of the
firing stroke. For example, when advancing the firing element, the
motor can incrementally, or slowly, increase the firing speed at
the beginning of the firing stroke, and can incrementally, or
slowly, decrease the firing speed as the firing element completes
the forward portion of the firing stroke. Furthermore, in various
embodiments, the motor can immediately or substantially immediately
generate the maximum torque and/or speed when retracting the firing
element. The motor can utilize the additional set of coils 6008
(FIGS. 65(a)-(c)) to max-out the torque generated at the beginning
of retraction, for example.
[0327] Referring to FIG. 68, the control system can control the
firing element to move at a slower speed during a trial segment
5912 of the firing stroke. For example, when advancing the firing
element, the firing element can initially move at a slower speed to
ensure the selection and/or the placement of the end effector is
appropriate for the targeted tissue. Furthermore, as described in
greater detail herein, a surgeon can engage an actuator, such as a
switch or a button, for example, to actuate the motor and initiate
opening and closing of the end effector jaws, movement of the
firing element, and/or articulation of the loading unit, for
example. Initiation of a trial segment, such as the trial segment
5912 indicated in FIG. 68, for example, when the actuator is
engaged and at the beginning of a motor-driven action can allow the
surgeon to "trial" the surgical action, to ensure that the intended
and/or appropriate surgical action has been initiated. For example,
in certain embodiments, a first button can initiate motor-driven
articulation in a first direction, and a second button can initiate
motor-driven articulation in a second direction. When the surgical
instrument is rotated and/or oriented "upside down" the placement
of the first and second buttons can rotate and/or become reversed
from the standard placements as viewed from the operator's
perspective. If the first direction is the intended articulation
direction, it may be desirable to ensure the loading unit is being
articulated in the first direction, i.e., that the first button was
in fact actuated, during a trial segment. Similarly, if the second
direction is the intended articulation direction, it may be
desirable to ensure the loading unit is being articulated in the
second direction, i.e., that the second button was actuated, during
a trial segment. In certain embodiments, a trial segment during the
initial portion of a surgical action can provide time for the
surgeon to change and/or modify the surgical action if a
non-intended surgical action has been initiated. As described in
greater detail herein, a pulse width modulation circuit, such as
pulse width modulation circuit 6022, for example, can accomplish
the trial segment during an initial portion of a surgical
action.
[0328] As discussed above, the motor controller can be configured
to utilize pulse width modulation to operate the motor 6004. In
various instances, the motor controller can utilize the same pulse
width modulation for the primary set of coils 6006 and the
secondary set of coils 6008, for example. In other instances, the
motor controller can utilize a first pulse width modulation signal
for the primary set of coils 6006, and a second, or different,
pulse width modulation signal for the secondary set of coils 6008.
In some instances, the motor controller can utilize a pulse width
modulation signal for one of the sets of coils 6006, 6008, but not
the other. Moreover, the teachings discussed herein can be adapted
to motors having more than two sets of coils. For instance, the
motor controller can utilize a plurality of pulse width modulation
signals to operate a plurality of coil sets.
[0329] In various embodiments, the motor can be a brushed DC motor
or a brushless DC motor, for example. In certain embodiments, the
motor can be a stepper motor, such as a hybrid stepper motor, for
example. Stepper motors can provide rotation control, such that an
encoder is not necessary. Elimination of the encoder can reduce
cost and/or complexity to the motor, for example. Referring to
FIGS. 69 and 70, the motor can be a simplified stepper motor. For
example, the motor can comprise four electromagnetic poles spaced
around the perimeter. Referring now to FIGS. 71-74(c), the motor
can be a hybrid stepper motor. The hybrid stepper motor can
comprise permanent magnets and electromagnets, for example.
[0330] Prior surgical instrument arrangements disclosed in, for
example, Zemlok '763 and Zemlok '344 employ two separate motors.
One motor is employed, for example, to advance the drive member
distally through the loading unit which results in the closing of
the anvil, cutting of tissue and firing of staples from the staple
cartridge supported in the loading unit. The other motor is
employed to articulate the loading unit about an articulation
joint. Further details relating to motors used for articulating
loading unit arrangements are also disclosed in U.S. Pat. No.
7,431,188, the entire disclosure of which is incorporated by
reference herein. The use of two motors in such devices may
increase the complexity and add to the overall expense of the
surgical instrument. For example, such arrangements may double the
number of retraction systems and other mechanisms that could fail
during use. The surgical instrument 810 depicted in FIGS. 29-31
employs a single motor which may be selectively employed to fire
and articulate a surgical end effector configured to perform at
least one surgical procedure in response to firing motions applied
thereto.
[0331] In at least one form, for example, the surgical instrument
810 may employ many of the same components employed in the various
surgical instruments described in detail herein. For example, the
surgical instrument 810 includes a housing 12 that operably
supports a motor 100 therein that is configured to generate rotary
actuation motions. The motor 100 is operably coupled to a gear
assembly 820 that has a selectively positionable drive coupler
assembly 840 associated therewith which will be described in
further detail below. The surgical instrument 810 may further
include an articulation system, generally designated as 859 that
operably interfaces with the elongated shaft assembly for applying
articulation motions to the surgical end effector. In one form, for
example, the articulation system 859 may include an articulation
actuation mechanism, generally designated as 860 which may be
substantially similar to those articulation actuation mechanisms
disclosed in Zemlok '763 and/or Zemlok '344 and/or U.S. Pat. No.
7,431,188 except for those differences discussed below. For
example, the housing 12 may include a barrel portion 90 that has a
rotatable member 92 mounted thereon. The rotatable member 92 may
interface with a proximal end of the elongated shaft assembly to
facilitate rotation of the elongated shaft assembly relative to the
housing 12. The rotatable member 92 may operably support an
articulation knob and slip clutch arrangement as disclosed in U.S.
Pat. No. 7,431,188. A main articulation gear 94 of that arrangement
is represented by broken lines in FIGS. 29 and 30. The main
articulation gear 94 may be connected to a main shaft 95 by a slip
clutch as described in the aforementioned U.S. Pat. No. 7,431,188
such that rotation of the main articulation gear 94 will cause
corresponding rotation of main shaft 95. As further described
therein, the articulation knob may serve as an articulation
position indicator. The main shaft 95 operably interfaces with a
J-channel member 96 that operably interfaces with the proximal end
of an articulation link assembly 97. In one form, the articulation
link assembly 97 may comprise a proximal articulation link 98 that
interfaces with the articulation link 70 (FIG. 3) in the loading
unit 20.
[0332] The articulation mechanism 860 may further include an
articulation drive train arrangement 870 that operably interfaces
with the main articulation gear 94 and the drive coupler assembly
840. As can be seen in FIGS. 29 and 30, the articulation drive
train arrangement 870 may include an articulation drive shaft 872
that is attached to an output of the drive coupler assembly 840 as
will be discussed in further detail below. A first articulation
drive gear 873 is attached to the articulation drive shaft and is
in meshing engagement with a central gear race 875 on a second
articulation transfer gear 874 that is rotatably supported within
the rotatable member 92. Thus, rotation of the first articulation
drive gear 873 results in rotation of the second central
articulation transfer gear 874. As can be further seen in FIGS. 29
and 30, a "third" articulation shaft gear 877 is mounted to a
second articulation shaft 876 that has a "fourth" articulation worm
gear 878 thereon. The third articulation shaft gear 877 is in
meshing engagement with the second central articulation transfer
gear 875 such that rotation of the first articulation drive gear
873 ultimately results in the rotation of the third articulation
shaft gear 877 and the second articulation shaft 876. The fourth
articulation worm gear 878 is in meshing engagement with the main
articulation gear 94 such that rotation of the fourth articulation
worm gear 878 results in rotation of the main articulation drive
gear 94 and ultimately application of articulation motions to the
articulation link assembly 97. As will be discussed in further
detail below, the articulation drive shaft 872 is rotated by the
motor 100 when the drive coupler assembly 840 is in an articulation
control orientation.
[0333] As can be seen in FIG. 31, the motor 100 is operably coupled
to the gear assembly 820. The gear assembly 820 may include a gear
box housing 822 that is coupled to the motor 100. For example, the
gear box housing 822 may be coupled to the motor housing 101 by
screws 103 or other mechanical fasteners and/or fastener
arrangements. The gear assembly 820 may comprise a planetary gear
arrangement 821 that is operably coupled to the motor shaft 107. In
one arrangement for example, a ring gear 823 may be formed on the
inner surface of the gear box housing 822. A primary sun gear 821
is coupled to the motor shaft 107. The primary sun gear 821 is in
meshing engagement with a plurality of first planetary gears 825
that are supported on a first planetary gear carrier 824 such that
they are also in meshing engagement with the ring gear 823. A first
sun gear 826 is formed on or otherwise attached to the first
planetary gear carrier 824 and is in meshing engagement with a
plurality of second planetary gears 828 that are supported on a
second planetary gear carrier 827. The second planetary gears 828
are also supported in meshing engagement with the ring gear 823. A
second sun gear 829 is formed on or otherwise attached to the
second planetary gear carrier 827 and is in meshing engagement with
a plurality of third planetary gears 831. The third planetary gears
831 are supported on a third planetary gear carrier 830 and are
supported in meshing engagement with the ring gear 823. A third sun
gear 833 is formed on or is otherwise attached to a shaft extension
832 on the third planetary gear carrier 830 and is in meshing
engagement with a plurality of fourth planetary gears 835 that are
attached to a coupler gear that comprises a fourth planetary gear
carrier 834 that is rotatably supported on the shaft extension 832.
In addition, a thrust bearing 836 may be journaled on the shaft
extension 832 between the fourth planetary gear carrier 834. The
fourth planetary gears 835 are in meshing engagement with an output
shaft unit 850 that is rotatably supported by the gear box housing
822. A second thrust bearing 836 may be supported between the
fourth planetary gears and the output shaft unit 850 as can be seen
in FIG. 30. The fourth planetary gears 835 are supported in meshing
engagement with an inner gear race 854.
[0334] In the illustrated embodiment, the output shaft unit 850 is
operably coupled to a clutch 230 of the type and construction
disclosed in Zemlok '763 which has been herein incorporated by
reference in its entirety. Further details regarding the
construction and operation of such clutch 230 may be obtained from
that publication. In an alternative embodiment, however, the clutch
230 may be replaced with a shaft-to-shaft coupler or sleeve
arrangement that serves to facilitate the coupling of the output
shaft unit 850 directly to the drive tube 102.
[0335] Referring again to FIG. 31, a primary articulation drive
gear 837 is attached to the articulation drive shaft 872 and is in
meshing engagement with an external gear ring 838 on the fourth
planetary gear carrier 834. In various forms, the drive coupler
assembly 840 may further include a coupler selector member 842 that
is movably coupled to or otherwise movably supported by the gear
box housing 822 or other portion of housing 812. In at least one
arrangement, the coupler selector member 842 may be formed with a
first drive shaft retainer portion 844 and a first articulation
shaft retainer portion 846. The first drive shaft retainer portion
844 comprises a grooved, roughened, etc. area that is configured to
non-movably engage a second drive shaft retainer portion 845 on the
output shaft unit 850. Similarly, the first articulation shaft
retainer portion 846 comprises a grooved, roughened, etc. area that
is configured to non-movably engage a second articulation shaft
retainer portion 847 on the fourth planetary gear carrier 834.
[0336] Operation of the coupler assembly 840 may be understood from
reference to FIGS. 29 and 30. As can be seen in FIG. 29, the
coupler selector member 842 is pivoted to the articulation position
wherein the first articulation shaft retainer portion 846 is in
non-movable engagement with the second articulation shaft retainer
portion 847 on the output shaft unit 850. When in that position,
the output shaft unit 850 is prevented from rotating about the
longitudinal axis LA-LA. Thus, when in that position, operation of
motor 100 will result in the rotation of the third sun gear 833
which is in meshing engagement with the fourth planetary gears 835.
Rotation of the fourth planetary gears 835 will result in the
rotation of fourth planetary gear carrier 834 which can freely
rotate. Such rotation of the fourth planetary gear carrier 834 will
also result in the rotation of the primary articulation gear 837
that is coupled to the articulation drive shaft 872. Rotation of
articulation drive shaft 872 will cause the first articulation
drive gear 873 to rotate and drive the second articulation transfer
gear 874. Rotation of the second articulation transfer gear 874
results in rotation of the third articulation transfer gear and the
fourth articulation worm gear 878. Rotation of the fourth
articulation worm gear 878 will drive the main articulation gear 94
which will result in the application of axial articulation motions
to the articulation links 97, 70 which ultimately results in the
articulation of the loading unit 20 about the articulation joint.
Rotation of the motor drive shaft 107 in a first rotary direction
will result in articulation of the loading unit in a first
articulation direction and rotation of the motor drive shaft 107 in
an opposite rotary direction will result in articulation of the
loading unit in a second articulation direction that is opposite to
the first articulation direction.
[0337] Referring next to FIG. 30, the coupler selector member 842
is pivoted to the drive or firing position wherein the first drive
shaft retainer portion 844 is in non-movable engagement with the
second drive shaft retainer portion 845 on the fourth planetary
gear carrier 834. When in that position, the fourth planetary gear
carrier 834 is prevented from rotating about the longitudinal axis
"LA-LA". Thus, when in that position, operation of motor 100 will
result in the rotation of the third sun gear 833. Third sun gear
833 is in meshing engagement with the fourth planetary gears 835
supported on the fourth planetary gear carrier 834. Because the
fourth planetary gear carrier 834 is prevented from rotating by
virtue of the non-movable engagement between the first articulation
shaft retainer portion 846 and the second articulation shaft
retainer portion 847 on the fourth planetary gear carrier 834,
rotation of the fourth planetary gears 835 will result in rotation
of the output shaft unit 850. Output shaft unit 850 may be coupled
to the drive tube 102 by the clutch assembly 230 or by a direct
coupling. Thus rotation of the output shaft unit 850 results in
rotation of the drive tube 102. As discussed above, rotation of the
drive tube 102 results in the axial movement of the firing rod (not
shown in FIG. 31). Rotation of the motor drive shaft 107 in a first
rotary direction will result in the distal advancement of the
firing rod and rotation of the motor drive shaft 107 in an opposite
rotary direction will result in the proximal movement of the firing
rod. In various embodiments, closure of the loading unit 20 jaws,
e.g., pivoting of the anvil assembly 22 relative to the carrier 24,
can couple and/or decouple the motor 100 to the articulation system
and/or the firing system of the surgical instrument 10. For
example, closure of the anvil assembly 22 relative to the carrier
24 can decouple the motor 100 from the articulation system, e.g.
from the articulation drive shaft 872, and can couple the motor 100
to the firing system, e.g., to the output shaft unit 850.
Furthermore, opening of the anvil assembly 22 relative to the
carrier 24 can decouple the motor 100 from the firing system, and
can couple the motor 100 to the articulation system. In such
embodiments, the motor 100 can affect articulation of the loading
unit 20 when the loading unit 20 is open, and the motor 100 can
affect firing of the firing rod when the loading unit 20 is closed.
The surgical instrument 10 can include a sensor and/or a selector,
for example. In certain embodiments the sensor can detect closure
of the loading unit 20 jaws. Furthermore, the sensor can be in
signal communication with the selector, such as coupler selector
member 842. The selector can couple and/or decouple the motor 100
to the articulation system and/or the firing system when the anvil
assembly 22 opens and/or closes relative to the carrier 24, for
example. Various powered surgical instruments that employ the
various drive coupler arrangements disclosed herein may represent
vast improvements over prior powered surgical instruments that
employ multiple motors to articulate the end effector and fire the
end effector drive member.
[0338] For example, at least one surgical instrument comprises an
elongated shaft assembly that defines a longitudinal tool axis. A
surgical end effector may be operably coupled to the elongated
shaft assembly for selective articulation relative thereto. The
surgical end effector may be configured to perform at least one
surgical procedure in response to firing motions applied thereto.
An articulation system may operably interface with the elongated
shaft assembly for applying articulation motions to the surgical
end effector. A firing member assembly may operably interface with
the elongated shaft assembly to apply the firing motions to the
surgical end effector. The surgical instrument may further comprise
a motor that is configured to generate rotary actuation motions. A
drive coupler assembly may interface with the motor and the
articulation system such that when the drive coupler assembly is in
a first configuration, operation of the motor will result in the
application of the actuation motions to the articulation system
resulting in articulation of the surgical end effector relative to
the longitudinal tool axis and when the drive coupler assembly is
in a second configuration, operation of the motor will result in
the application of actuation motions to the firing member assembly
causing the firing member assembly to apply at least one of the
firing motions to the surgical end effector.
[0339] Another surgical instrument example may comprise a handle
that has an elongated shaft assembly operably coupled thereto that
defines a longitudinal tool axis. A loading unit may be operably
coupled to the elongated shaft assembly and be configured to sever
and staple tissue in response to firing motions applied thereto.
The loading unit may be configured to be selectively articulated
relative to the longitudinal tool axis about an articulation joint.
The surgical instrument may further comprise an articulation system
that includes an articulation link assembly that is supported by
the elongated shaft assembly and is configured to operably
interface with an articulation joint portion in one of the
elongated shaft assembly and the loading unit. An articulation
actuation mechanism may be supported by the handle and interface
with the articulation link assembly to apply articulation actuation
motions thereto. The surgical instrument may further comprise a
firing member assembly that operably interfaces with the loading
unit to apply the firing motions thereto. A motor may be operably
supported by the handle and be configured to generate rotary
actuation motions. A drive coupler assembly may interface with the
motor and the articulation actuation mechanism such that when the
drive coupler assembly is in a first configuration, operation of
the motor will result in the application of the actuation motions
to the articulation system resulting in articulation of the loading
unit relative to the longitudinal tool axis and when the drive
coupler assembly is in a second configuration, operation of the
motor will result in the application of actuation motions to the
firing member assembly causing the firing member assembly to apply
at least one of the firing motions to the loading unit.
[0340] Still another surgical instrument example may comprise an
elongated shaft assembly that defines a longitudinal tool axis. A
surgical end effector may be operably coupled to the elongated
shaft assembly for selective articulation relative thereto. The
surgical end effector may be configured to perform at least one
surgical procedure in response to firing motions applied thereto.
An articulation system may operably interface with the elongated
shaft assembly for applying articulation motions to the surgical
end effector. A firing member assembly may operably interface with
the elongated shaft assembly to apply the firing motions to the
surgical end effector. A motor may be configured to generate rotary
actuation motions. The surgical instrument may further comprise
means for selectively applying an output motion from the motor to
each of the articulation system and the firing member assembly.
[0341] In certain motor-driven surgical instruments, a motor can
provide haptic feedback to the operator of the surgical instrument.
For example, rotation of the motor can generate vibratory motion or
noise, which can depend on the direction and/or speed of the
motor's rotation, for example. However, various motors may generate
minimal noise, and thus, haptic feedback to the surgeon can be
limited and/or may be unappreciated by the surgeon. For example,
various modification and/or improvements in motor and/or
transmission design may reduce the haptic noise generated by the
motor and/or the transmission. In such embodiments, it may be
advantageous to modify the motor and/or gear assembly operably
coupled to the motor to generate artificial, or intentional, haptic
feedback and/or other sensory feedback. In certain embodiments, the
surgical instrument can communicate the feedback to the surgeon
without requiring the surgeon to look away from the operating site.
For example, the motor and/or gears can generate haptic and/or
audible feedback to communicate with the surgeon. In such
embodiments, the operator need not look at a display screen, for
example, to ascertain an operating state or condition of the
surgical instrument. As described in greater detail herein, the
surgical instrument can communicate the rotational direction of the
motor, for example, which can correspond to the firing direction of
the firing member and/or the articulation direction of the loading
unit, for example. Additionally or alternatively, the surgical
instrument can communicate the speed and/or the position of the
firing member during a firing stroke, for example, and/or the speed
and/or degree of articulation of the loading unit, for example.
[0342] In various embodiments, as described in greater detail
herein, a motor can be operably coupled to a firing assembly and/or
an articulation assembly. Referring to FIG. 168, the motor 7010 can
drive a motor shaft 7014, which can engage a gear assembly 7020,
for example. In various embodiments, a key, such as key 7016 on the
motor shaft 7014, can engage a portion of the gear assembly 7020.
In certain embodiments, the gear assembly 7020 can include disks
7022, 7024, for example, which can be structured to rotate or spin
along with the motor shaft 7014 when engaged therewith via a key.
For example, the first disk 7022 can include a groove (not shown).
Furthermore, a first key (not shown) extending from the motor shaft
7014 can engage the groove in the first disk 7022 such that the
first disk 7022 rotates clockwise (CW) when the motor shaft 7014
rotates CW and rotates counterclockwise (CCW) when the motor shaft
7014 rotates CCW. In at least one embodiment, the first key can
remain engaged with the groove in the first disk 7022 throughout
the operation of the surgical instrument and/or motor thereof.
[0343] In certain embodiments, the first disk 7022 can be balanced
relative to its axis of rotation along the motor shaft 7014.
Referring still to FIG. 168, a mass, such as mass 7026, for
example, can extend from the first disk 7022 and may shift the
center of mass of the first disk 7022 off of the axis of rotation
of the first disk 7022. For example, the mass 7026 can extend away
from the motor shaft 7014 and/or away from the outer perimeter of
the first disk 7022. In other words, the mass 7026 can upset the
balance of the first disk 7022, result in a rotational unbalance of
the first disk 7022, and thus, generate a centrifugal force when
the first disk 7022 rotates with the motor shaft 7014.
Consequently, rotation of the first disk 7022 and mass 7026 can
generate haptic feedback, such as a vibration or wobble of the
surgical instrument housing and/or handle, for example. The haptic
feedback can correspond to an operating state or condition of the
surgical instrument. Furthermore, the haptic feedback generated by
the rotation of the first disk 7022 and the mass 7026 can depend on
the rotational speed of the motor shaft 7014. In such embodiments,
the firing speed and/or the articulation speed can also be
communicated to the surgeon, for example. For instance, the first
disk 7022 can generate haptic feedback having a higher frequency
when the motor shaft 7014 is rotated faster and a lower frequency
when the motor shaft 7014 is rotated slower.
[0344] Similar to the first disk 7022, in certain embodiments, the
second disk 7024 can be balanced relative to its axis of rotation
on the motor shaft 7014. Referring still to FIG. 168, however, a
mass, such as mass 7028, for example, can extend from the second
disk 7024 and may shift the center of mass thereof. For example,
the mass 7028 can extend away from the motor shaft 7014 and/or away
from the outer perimeter of the second disk 7024. In other words,
the mass 7028 can upset the balance of the second disk 7024, result
in a rotational unbalance of the second disk 7024, and thus,
generate a centrifugal force when the second disk 7024 rotates with
the motor shaft 7014. Consequently, rotation of the second disk
7024 and mass 7028 can generate haptic feedback, such as a
vibration or wobble of the surgical instrument housing and/or
handle, for example. The haptic feedback can correspond to an
operating state or condition of the surgical instrument.
Furthermore, the haptic feedback generated by the rotation of the
second disk 7024 and mass 7028 can depend on the rotational speed
of the motor shaft 7014. In such embodiments, the firing speed
and/or the articulation speed can also be communicated to the
surgeon, for example. In various embodiments, the first and/or
second disks 7022, 7024 can include additional masses, similar to
masses 7026 and/or 7028, for example, which can further contribute
to a haptic response of the surgical instrument housing and/or
handle, for example. Furthermore, in some embodiments, the motor
shaft 7014 can operably engage additional and/or different disks of
the gear assembly 7120 to selectively generate additional and/or
different haptic feedback.
[0345] Referring still to FIG. 168, the second disk 7024 can
include an inner perimeter 7026. In various embodiments, a second
key 7016 can extend from the motor shaft 7014, and can operably
engage the second disk 7024 via the inner perimeter 7030. The inner
perimeter 7030 can include a plurality of planar surfaces 7032 and
a plurality of arcuate surfaces 7034 between adjacent planar
surfaces 7032, for example. Each pair of planar and arcuate
surfaces 7032, 7034 can define a groove, which can be structured to
receive the second key 7016. In certain embodiments, when the key
7016 rotates in a first direction, the key 7016 can abut a planar
surface 7032 and become held and/or retained in a groove of the
second disk 7024. In such an arrangement, the second disk 7024 can
rotate in the first direction along with the motor shaft 7014.
Furthermore, in certain embodiments, when the key 7016 rotates in a
second direction opposite to the first direction, the key 7016 can
rotate past the arcuate surfaces 7034 and may become held and/or
retained in the grooves in the inner perimeter 7030. In other
words, the key 7016 can rotate relative to the second disk 7024. In
such an arrangement, the motor shaft 7014 can rotate in the second
direction relative to the second disk 7024. Accordingly, the key
7016 may only engage the second disk 7024 and cause the second disk
7024 to rotate when the motor shaft 7014 rotates in the first
direction. In certain embodiments, the first direction can
correspond to a CW rotation, and in other embodiments, the first
direction can correspond to a CCW rotation.
[0346] As described herein, because engagement of the second disk
7024 can depend on the rotational direction of the motor shaft
7014, the second disk 7024 may only rotate when the motor shaft
7014 rotates in one direction, such as when the motor 7010 drives
the firing member in one direction and/or rotates the loading unit
in one direction. For example, the second disk 7024 may only rotate
when the motor 7010 retracts the firing member or rotates the
loading unit CW, for example. Such selective engagement of the
second disk 7024 can affect the haptic feedback generated by the
surgical instrument. In other words, different and/or greater
haptic feedback can result based on the selective engagement of the
second disk 7024. For example, in embodiments where the second disk
7024 only rotates when the motor 7010 rotates to retract the firing
member, a greater haptic feedback can be generated during
retraction than during advancement of the firing member. During
retraction, the second disk 7024 can also contribute to the
generation of haptic feedback, which can result in a greater or
larger summation of feedback forces. In such embodiments, the
greater haptic feedback generated by the first and second disks
7022, 7024 can communicate to the surgeon that the firing member is
being retracted by the motor 7010. In various embodiments, in view
of the above, only the first disk 7022 may be rotated when the
motor shaft 7014 is rotated in one direction and both disks 7022,
7024 may be rotated when the motor shaft 7014 is rotated in the
opposite direction. As such, the disks 7022, 7024 may generate
different feedback when the motor shaft 7014 is rotated in
different directions.
[0347] Referring now to FIG. 169, in certain embodiments, the motor
7010 can drive the motor shaft 7014, which can engage a gear
assembly 7120. In various embodiments, a key, such as the key 7016
on the motor shaft 7014, for example, can engage the gear assembly
7120. Similar to the gear assembly 7020, the gear assembly 7120 can
include a plurality of disks, such as a first disk 7122 and a
second disk 7124. The first and second disks 7122, 7124 can be
structured to rotate or spin with the motor shaft 7014 when
selectively engaged therewith via a key. For example, the first
disk 7122 can include a groove (not shown). Further, a first key
(not shown) extending from the motor shaft 7014 can engage the
groove of the first disk 7122 such that the first disk 7122 rotates
with the motor shaft 7014. In certain embodiments, the first key
can be non-disengageable from the groove of the first disk 7122
during use. The second disk 7124 can include an inner perimeter
7130, similar to the inner perimeter 7030 of second disk 7024, for
example. The inner perimeter 7130 can comprise a plurality of
planar surfaces 7132 and a plurality of arcuate surfaces 7134. As
described herein with respect to FIG. 168, the key 7016 can
selectively engage and disengage the inner perimeter 7130 of the
second disk 7124 depending on the rotational direction of the motor
shaft 7014. For example, when the motor shaft 7014 rotates in a
first direction, the key 7016 can engage the second disk 7124
causing the second disk 7124 to rotate with the motor shaft 7014.
Furthermore, when the motor shaft 7014 rotates in a second
direction, the key 7016 can remain disengaged from the second disk
such that the key 7016 can rotate relative to the second disk 7024
within the inner perimeter 7130 thereof.
[0348] In various embodiments, the first disk 7122 can include at
least one pick 7126, and the second disk 7124 can also include at
least one pick 7128. When the disks 7122, 7124 rotate, the picks
7126, 7128 can strike elements of an audio feedback generator 7140.
For example, the picks 7126, 7128 can strike clickers 7142, 7144 of
the audio feedback generator 7140. In various embodiments, the pick
or picks 7126 of the first disk 7122 can strike and deflect the
first clicker 7142 when the first disk 7122 rotates, and the pick
or picks 7128 of the second disk 7124 can strike and deflect the
second clicker 7144 when the second disk 7124 rotates. Impact and
deflection of the clickers 7142, 7144 can cause the clickers 7142,
7144 to resonate and generate an auditory signal. In other words,
the rotation of the first and second disks 7122 can generate audio
feedback. Furthermore, the rotational speed of the rotating disks
7122, 7124 and/or the number and arrangement of picks extending
from the first and second disks 7122, 7124 can affect the frequency
of the auditory signals. In such embodiments, the speed of the
motor and corresponding firing speed of the firing element and/or
articulation of the speed of the loading unit can be communicated
to the surgeon, for example.
[0349] Referring primarily to FIGS. 170 and 171, in various
embodiments, the geometry of the picks 7126, 7128 can affect the
auditory signals generated by the audio feedback generator 7140.
For example, the picks 7126, 7128 can each include a non-dampening
surface 7150 and a dampening surface 7152. The non-dampening
surface 7152 can include a planar surface, for example, and the
dampening surface 7152 can include an arcuate surface, for example.
In various embodiments, where the non-dampening surface 7150 of the
pick 7126 rotationally leads the dampening surface 7152 of the pick
7126 (FIG. 170), resonance of the clicker 7142 can be dampened
and/or stopped by the trailing dampening surface 7152 of the pick
7126. For example, the arcuate geometry of the dampening surface
7152 may contact the deflected clicker 7126 to prevent and/or
restrain vibration or resonance of the clicker 7126. Conversely,
where the dampening surface 7152 of the pick 7126 rotationally
leads the non-dampening surface 7150 of the pick 7126 (FIG. 171),
resonance of the clicker 7142 may not be dampened by the
non-dampening surface 7150 of the pick 7126. For example, the
planar geometry of the non-dampening surface 7150 can avoid and/or
limit contact with the deflected clicker 7126 such that resonance
of the clicker 7126 is permitted and/or less restrained. In other
words, the rotational direction of the disks 7122, 1724 and
associated picks 7126, 7128 can affect the auditory feedback
generated by the surgical instrument. Accordingly, the operator of
the surgical instrument can be informed of the operating state of
the surgical instrument during its use, and without requiring the
surgeon to look away from the surgical site. For example, the audio
signals can be dampened when the firing member is retracted, and
may not be dampened when the firing member is advanced. In other
embodiments, the audio signals can be dampened when the firing
member is advanced, and may not be dampened when the firing member
is retracted. Furthermore, in some embodiments, the dampened
auditory signals can correspond with articulation of the loading
unit in one direction, and the un-dampened auditory signals can
correspond with articulation of the loading unit in another
direction, for example. In various embodiments, at least one audio
feedback generator can be used alone and/or in combination with at
least one haptic feedback system. Furthermore, in some embodiments,
at least one haptic feedback system can be used alone and/or in
combination with at least one audio feedback generator. Audio
feedback and haptic feedback can communicate different operating
conditions to the surgeon and/or can provide duplicative feedback
to the surgeon regarding the same operating conditions, for
example.
[0350] In various embodiments, the surgical instrument can generate
feedback when the firing element approaches and/or reaches the end
of the firing stroke and/or when the loading unit approaches and/or
reaches the articulation limit. In various embodiments, such
feedback can be different and/or additional to the feedback
generated throughout a firing stroke and/or when the loading unit
is articulated. Accordingly, the surgical instrument can notify the
operator that the firing stroke is near completed and/or completed,
for example, and/or can notify the operator that the loading unit
is near the articulation limit and/or has reached the articulation
limit.
[0351] Referring now to FIG. 172, the motor 7010 and the motor
shaft 7014 can be operably engaged with the gear assembly 7120, as
described in greater detail above. Furthermore, the disks 7122,
7124 of the gear assembly 7120 can contact an audio feedback
generator 7240, which can be similar to audio feedback generator
7140, for example. For example, the picks 7126, 7128 on the disks
7122, 7124 can deflect the clickers 7242, 7244 of the audio
feedback generator 7240 causing the clickers 7242, 7244 to resonate
and generate auditory feedback. Furthermore, the audio feedback
generator 7240 can move or translate relative to the gear assembly
7120. As described in greater detail below, the audio feedback
generator 7240 can selectively move into and/or out of engagement
with the clickers 7242, 7244 on the disks 7122, 7124 to selectively
generate auditory signals. In other embodiments, the motor, gear
assembly, and/or the disks thereof can move, such that the picks of
the disks are selectively moved into and/or out of engagement with
the clickers of an audio feedback generator to selectively generate
auditory signals.
[0352] In various embodiments, the audio feedback generator 7240
can translate in the surgical instrument as the firing member moves
during a firing stroke. For example, at the beginning of the firing
stroke, the audio feedback generator 7240 can be misaligned with
the picks 7126, 7128 of the disks 7122, 7124. Furthermore, as the
firing member moves distally and/or approaches the end of the
firing stroke, the audio feedback generator 7240 can move toward
and/or into alignment with the picks 7126, 7128 of the disks 7122,
7124. In such embodiments, the audio feedback generator 7240 can
generate auditory feedback when the firing member is near and/or at
the end of the firing stroke. Referring to FIG. 173, for example,
the feedback generator can generate feedback when the firing member
is within a range of positions near and/or at the end of the firing
stroke, for example, to communicate the position of the firing
member to the surgeon. In such embodiments, the surgical instrument
can communicate the end of the firing stroke to the operator. For
example, referring again to FIG. 172, at least one pick 7126, 7128
can be aligned with at least one clicker 7242, 7244 as the firing
member approaches the distal end of the firing stroke. At that
time, the surgical instrument can generate a feedback to
communicate the position of the firing member to the surgeon. When
each pick 7126, 7128 is aligned with one of the clickers 7242,
7242, a greater and/or different feedback can be communicated to
the surgeon. Furthermore, as the firing member is retracted, at
least one pick 7126, 7128 can again become misaligned with a
clicker 7242, 7244 such that a reduced and/or different feedback is
communicated to the surgeon. Accordingly, as the feedback generator
moves through the firing stroke, the feedback generator can
communicate varying feedback to the operator based on the position
of the firing member. Furthermore, the gear assembly 7120 can
include additional disks and/or picks, which can move into and/or
out of engagement with the audio feedback generator 7240, and/or
the audio feedback generator 7240 can include additional clickers,
which can move into and/or out of engagement with the picks. In
various embodiments, an audio feedback generator can communicate
alternative and/or additional positions of the firing member to the
surgeon. For example, an audio feedback generator can communicate
auditory feedback at the midpoint and/or incremental points along
the length of the firing and/or retraction path.
[0353] Referring now to FIGS. 174 and 175, a movable feedback
generator can also be utilized to communicate the articulation
limit of the loading unit to the surgeon. For example, the audio
feedback generator 7240 depicted in FIG. 172, for example, can
translate as the loading unit articulates. For example, when the
loading unit is in an unarticulated configuration, the audio
feedback generator 7240 can be misaligned with the picks 7126, 7128
of the disks 7122, 7124. Furthermore, as the loading unit
articulates, the audio feedback generator 7240 can move toward
and/or into alignment with the picks 7126, 7128 of the disks 7122,
7124. In such embodiments, the audio feedback generator 7240 can
generate auditory feedback when the loading unit is near and/or at
the articulation limit. For example, referring again to FIGS. 174
and 175, the feedback generator can generate feedback when the
firing member is within a range of positions near and/or at the end
of the firing stroke to communicate the position of the firing
member to the surgeon. In such embodiments, the surgical instrument
can communicate the articulation limit to the operator. For
example, referring again to FIG. 172, at least one pick 7126, 7128
can be aligned with at least one clicker 7242, 7244 as the loading
unit approaches its articulation limit, for example, approaches
forty-five degrees. At that time, the surgical instrument can
generate a feedback to communicate the position of the firing
member to the surgeon. When the loading unit is nearer and/or at
the articulation limit, each pick 7126, 7128 can be aligned with
one of the clickers 7242, 7244, and a greater and/or different
feedback can be communicated to the surgeon. Furthermore, as the
loading unit is articulated back toward the unarticulated, neutral
position, at least one pick 7126, 7128 can again become misaligned
with a clicker 7242, 7244 such that a reduced and/or different
feedback is communicated to the surgeon. Accordingly, as the
feedback generator moves through the firing stroke, the feedback
generator can communicate varying feedback to the operator based on
the configuration of the loading unit.
[0354] In various embodiments, it may be advantageous to protect
certain components of a surgical instrument from fluid contact. For
example, unintentional contact with a bodily fluid during use can
damage the surgical instrument, and may limit and/or shorten the
lifespan of the surgical instrument. Furthermore, it may be
advantageous to protect certain components of a surgical instrument
from fluid contact during sterilization. For example, unintentional
contact with a sterilizing and/or cleaning fluid can damage the
surgical instrument, and may prevent and/or limit the reusability
of a surgical instrument. In various embodiments, certain
components of a surgical instrument can be sealed and/or protected
from fluid contact. For example, electronics in the surgical
instrument can be sealed in epoxy for protection from fluids.
Moving components of the surgical instrument, such as portions of
the motor and/or the gear assembly, for example, can also be sealed
and/or protected from fluid contact. Such a seal can accommodate
the rotation of the various moving components, for example.
Furthermore, in various embodiments, such a seal can also
facilitate heat transfer such that the heat generated during the
operation of the surgical instrument is more effectively
dissipated.
[0355] Referring now to FIGS. 185 and 186, in certain embodiments,
a motor 7510 and/or a gear assembly 7520 can be sealed and/or
protected from fluids during use and/or during sterilization
treatments. The motor 7510 can be similar to the motor 100, for
example, and the gear assembly 7520 can be similar to the gear
assembly 170, for example. To seal and protect the motor 7510, a
motor housing, such as a rubber sleeve, for example, may be
positioned around the motor 7510 within the housing 12 (FIG. 1) of
the surgical instrument 10 (FIG. 1). Such a rubber sleeve may limit
heat transfer from the motor 7510, and the motor 7510 may be prone
to overheating. In other embodiments, referring again to FIGS. 185
and 186, the motor housing can comprise a clam-shell cover 7516,
for example, which can be positioned around the motor 7510. In
various embodiments, the clam-shell cover 7516 can include at least
two portions, which can be hinged and/or clasped together, for
example. The clam-shell cover 7516 can permit rotation of the motor
7510 and/or a motor shaft. Additionally, in certain embodiments,
the clam-shell cover 7516 can facilitate heat transfer from the
motor 7510 held herein. A contact arrangement 7512 (FIG. 186),
similar to the contact arrangement 210, for example, can be
employed to supply electrical current to the motor 7510. The
contact arrangement 7512 can include positive and negative annular
contacts 7514a, 7514b (FIG. 186), for example, which can operably
connect to fixed positive and negative contacts 7518a, 7518b (FIG.
186) held by the clam-shell cover 7516, for example. Furthermore,
the clam-shell cover 7516 can include an annular seal or gasket
7519, which can abut the perimeter of the motor 7510, and seal the
motor 7510 and contact arrangement 7512 within the clam-shell cover
7516, for example. In certain embodiments, the clam-shell cover
7516 can comprise a metallic material, which can facilitate heat
transfer from the motor 7510, for example, and may prevent
overheating and/or damage to the motor 7410.
[0356] Referring still to FIGS. 185 and 186, the gear assembly 7520
can also be sealed and/or protected from fluids during use and/or
sterilization. For example, a gasket 7522 can be positioned between
the motor 7510 and the housing of the gear assembly 7520, such that
the motor 7510 and gear assembly 7520 form a fluid-tight seal.
Furthermore, a sealing sleeve 7530 can be positioned around the
housing of the gear assembly 7520. The sealing sleeve 7530 can
include a rim 7536, which can abut the clam-shell cover 7516 and/or
the motor 7510 to provide a fluid-tight seal therebetween. The
sealing sleeve 7530 can also include an opening 7532 for an output
shaft 7524. For example, the output shaft 7524 of the gear assembly
7520 can extend through the opening 7532, and fins 7534 can extend
toward the output shaft 7524 to provide a fluid-tight seal while
permitting rotation of the output shaft 7524 within the opening
7532. In various embodiments, the sealing sleeve 7530 and/or the
rims 7536, gaskets, and/or fins 7534 thereof can comprise rubber
and/or another suitable material for forming a fluid-tight seal. In
various embodiments, a mounting bracket or motor retainer 7540,
similar to the retainer 190, for example, can hold the sealed gear
assembly 7520 and the motor 7510 within the housing 12 (FIG. 1) of
the surgical instrument 10 (FIG. 1).
[0357] FIGS. 32-37 illustrate another surgical instrument 910 that
may include many of the features of the other surgical instruments
disclosed herein. In at least one form, the surgical instrument 910
may include an articulation actuation mechanism, generally
designated as 860, which may be substantially similar to those
articulation mechanisms disclosed in Zemlok '763, Zemlok '344
and/or U.S. Pat. No. 7,431,188 except for those differences
discussed below. In other arrangements, the surgical instrument may
include various forms of other articulation actuation mechanisms as
described herein. As can be seen in FIG. 32, the instrument 910
includes a housing 12 that may include a barrel-shaped mounting
portion 90 that has rotatable member 92 mounted thereon. The
rotatable member 92 interfaces with a proximal end of the elongated
shaft assembly 16 to facilitate rotation of the elongated shaft
assembly 16 relative to the housing 12. Such arrangement permits
the clinician to selectively rotate the elongated shaft assembly 16
and the loading unit 20 (or other form of surgical end effector)
coupled thereto about the longitudinal tool axis "LA-LA". The
rotatable member 92 may be non-removably mounted on the barrel
portion 90 or it may be designed to be selectively detached
therefrom.
[0358] As disclosed herein, depending upon the type and/or
construction of the surgical end effector employed, it may be
desirable to supply electric current to the end effector. For
example, the end effector may employ sensor(s), light(s),
actuators(s), etc. that require electricity for activation. In such
arrangements, however, the ability to rotate the surgical end
effector about the longitudinal tool axis "LA-LA" can be severely
limited because the conductor system transporting power to the
surgical end effector or loading unit through the elongated shaft
from a source of electrical power may become wound up and severely
damaged--particularly in instances where the elongated shaft has
been rotated for more than one revolution. Various surgical
instruments disclosed herein may employ a conductor management
system generally designated as 930 that may avoid those
problems.
[0359] Referring again to FIG. 32, the surgical instrument 910 may
be powered by an electrical power source 200. The electrical power
source may, for example, be of the type described in further detail
in Zemlok '763. For example, the electrical power source 200 may
comprise a rechargeable battery (e.g., lead-based, nickel-based,
lithium-ion based, etc.). It is also envisioned that the electrical
power source 200 may include at least one disposable battery. In at
least one arrangement, for example, the disposable battery may be
between about 9 volts and about 30 volts. FIG. 32 illustrates one
example wherein the electrical power source 200 includes a
plurality of battery cells 202. The number of battery cells
employed may depend upon the current load requirements of the
instrument 910. It is also conceivable that the electrical power
source may comprise a source of alternating current available in
the surgical suite. For example, an external power cord and plug
(not shown) may be employed to transport alternating current from
an outlet in the surgical suite to various components, conductors,
sensors, switches, circuits, etc. in the surgical instrument
housing and/or end effector. In other applications, the surgical
instrument 910 may obtain power from, for example, a robotic system
to which it is attached or otherwise associated with.
[0360] As can be further seen in FIG. 32, the conductor management
system 930 may include a primary conductor member or wire 932 that
is coupled to or otherwise interfaces with the electrical power
source 200 for receiving power therefrom. The primary conductor
member 932 is coupled to a spiral, spool, and/or windable conductor
assembly 934 that is supported within the rotatable member 92. In
one arrangement, for example, the spiral conductor assembly 934 may
be formed or otherwise comprise a ribbon-like conductor 936 that is
wound in a spiral fashion in the manner depicted, for example, in
FIGS. 36 and 37. For example, the spiral conductor assembly 934 may
be fabricated from a spirally wound conductor that may have similar
attributes to that of a spirally wound spring such as, for example,
a torsion spring. In one form, for example, the conductor 936 may
be wound in successive revolutions or wraps as shown in FIGS. 36
and 37. In various arrangements, the conductor 936 may be wrapped
for one or more complete revolutions. For example, the conductor
936 illustrated in FIGS. 36 and 37 is configured in more than four
complete revolutions.
[0361] In various forms, the conductor 936 has a first end 938 that
may be fixed, for example, to the barrel portion 90 of the housing
12. In addition, the conductor 936 further has a second end 940
that is attached to or otherwise supported by the rotatable member
92 for rotational travel therewith. Thus, when the rotatable member
92 is rotated in a first rotatable direction about the barrel
portion 90, the spirally wound conductor 936 is wound up in a
tighter fashion. Conversely, when the rotatable member 92 is
rotated in a second rotatable direction, the degree of tightness of
the spirally wound conductor 936 may be lessened. In those
configurations wherein the rotatable member 92 is removably
supported on the barrel portion 90, the first end 938 of the
spirally wound conductor 936 may be removably supported in a slot
or other mounting cavity 942 in the barrel portion 90. See, e.g.,
FIGS. 36 and 37. In addition, the primary conductor member 932 may
be detachably coupled to the spiral conductor assembly 934 by a
connector assembly 933. In particular, a detachable connector
assembly 933 may be employed to couple the primary conductor member
932 to the first end of 938 of the spirally wound conductor 936 to
facilitate removal of the rotatable member 92 from the barrel
portion 90. In other arrangements wherein the rotatable portion 92
is not intended to be removed from the barrel portion, the first
end 938 of the spirally wound conductor 936 may be non-removably
affixed to the barrel portion 90 and the primary conductor member
932 may be permanently affixed (e.g., soldered) to the first end of
the spirally wound conductor 936.
[0362] The second end 940 of the spirally wound conductor 936 may
be non-removably affixed to the rotatable member 92 by adhesive,
mechanical retainers, snap features, etc. In alternative
arrangements, the second end 940 of the spirally wound conductor
936 may be removably supported in a slot or other mounting feature
provided in the rotatable member 92 to facilitate detachment of the
spirally wound conductor 936 from the rotatable portion 92. As can
be seen in FIGS. 32 and 33, a secondary shaft conductor member 944
is attached to the second end 940 of the spiral cable assembly 934.
The secondary shaft conductor member 944 may be supported within
the rotatable member 92 and extend through the hollow elongated
shaft assembly 16. For example, the secondary shaft conductor
member 944 may extend through the elongated shaft assembly 16 to
its distal end to interface with other conductors, sensors, powered
components, etc. associated with the surgical end effector, loading
unit, etc. attached thereto. Thus, when the clinician rotates the
rotatable member 92 relative to the housing 12, the spiral
conductor assembly 934 and more particularly, the spirally wound
conductor 936 will wind into a somewhat tighter spiral while
facilitating the application of power from the power source 200 to
the surgical end effector, loading unit, etc. If the clinician
rotates the rotatable member 92 relative to the housing 12 in an
opposite direction, the spirally wound cable 936 will somewhat
unwind while still facilitating the application of power from the
electrical power source 200 to the various components, sensors,
etc. on the surgical end effector, loading unit, etc.
[0363] As can be further seen in FIGS. 34 and 35, the conductor
management system 930 may further include a rotation limiter
assembly generally designated as 950. In at least one arrangement,
for example, the rotation limiter assembly 950 includes a limiter
member 952 that is movably attached to the rotatable member 92 and
is configured to threadably engage a threaded portion 99 on the
barrel 90 of the housing 12. The limiter 952 may include a pair of
opposing tabs 954 that are on each side of an axial fin portion 958
formed on the rotatable member 92 as shown in FIG. 33. Such
arrangement permits the limiter 952 to move axially within the
rotatable member 92 as the rotatable member 92 is rotated on the
barrel portion 90 of the housing 12. The opposite end 960 of the
limiter member 952 is configured to threadably engage the threaded
portion 99 of the barrel 90. An inwardly extending proximal stop
wall 962 of the rotatable member 92 and an inwardly extending
distal stop wall 964 serve to define a travel distance "TD" that
the limiter 942 may axially travel as the rotatable member 92 is
rotated on the barrel 90.
[0364] FIG. 33 illustrates the limiter 952 approximately midway
between the proximal stop wall 952 and the distal stop wall 954.
When in that position, rotation of the rotatable member 92 in a
first direction relative to the barrel portion 90 will result in
the axial travel of the limiter in the distal direction "DD" until
the limiter 952 contacts the distal stop wall 964 as shown in FIG.
34. Likewise, rotation of the rotatable member 92 in an opposite
direction relative to the barrel portion 90 results in the axial
travel of the limiter 952 in the proximal direction "PD" until it
contacts the proximal stop wall 962 of the rotatable member 92.
Such arrangement thereby limits the number of times that the
rotatable member 92 can be rotated completely around the barrel
portion 90 to prevent inadvertent damage of the spiral conductor
assembly 934. For example, the limiter assembly 950 may enable the
clinician to rotate the elongated shaft assembly and, more
particularly the rotatable member 92 for at least one full
revolution but not more than, for example, three full revolutions
about the barrel portion 90 in either direction. However, the
number of revolutions, or more particularly, the amount of
rotatable travel of the rotatable member 92 on the barrel 90 may be
adjusted by adjusting the magnitude of the travel distance
"TD".
[0365] FIG. 33 illustrates the limiter 952 in a "neutral" or
"central" position wherein the limiter is centrally disposed
between the distal stop wall 954 and the proximal stop wall 952. In
at least one form, biasing members 980 may be employed to bias the
limiter 952 into the neutral position when the elongated shaft
assembly 16 and rotatable member 92 are in a corresponding neutral
position. When the clinician applies a rotary motion to the
rotatable portion 92, the elongated shaft assembly 16 will rotate
in the manner described above. However, when the application of the
rotary motion to the rotatable member 92 and elongated shaft
assembly 16 is discontinued, the biasing members 980 will return
the limiter 952 to the neutral position.
[0366] For example, at least one surgical instrument may comprise a
housing that may include a rotatable member that is supported on a
mounting portion of the housing for rotation therearound through a
range of rotation. An elongated shaft assembly that defines a
longitudinal tool axis may be operably coupled to the rotatable
member for rotational travel therewith about the longitudinal tool
axis. The surgical instrument may further comprise a source of
electrical power and include a conductor management system. The
conductor management system may comprise a spool conductor assembly
that may be supported in the rotatable member and may include a
first conductor end that is fixed to the mounting portion of the
housing and a second conductor end that is fixed to the rotatable
member for rotation therewith through the range of rotation. The
conductor management system may further comprise a primary
conductor that may be supported within the housing and be
configured to transmit electrical power from the source of
electrical power to the spool conductor assembly. A shaft conductor
may be coupled to the spool conductor assembly for transmitting
electrical power to a distal end of the elongated shaft
assembly.
[0367] Another surgical instrument example may comprise a housing
that includes a rotatable member that is supported on a mounting
portion of the housing. The surgical instrument may further
comprise an elongated shaft assembly that defines a longitudinal
tool axis and which may be operably coupled to the rotatable member
for rotational travel therewith about the longitudinal tool axis.
The surgical instrument may further comprise a source of electrical
power and means for transferring power from the source of
electrical power through a conductor that extends through the
elongated shaft assembly. The surgical instrument may further
comprise means for limiting an amount of rotary travel of the
rotatable member about the mounting portion to a range of rotary
travel comprising at least one full revolution and not more than
three full revolutions about the mounting portion.
[0368] As outlined herein, an end effector can be attached to a
surgical instrument. As also outlined herein, the surgical
instrument can comprise a firing drive configured to fire staples
from an end effector including a staple cartridge. Turning now to
the exemplary embodiment depicted in FIG. 94, for example, a
surgical instrument 9000 can comprise a handle 9010 including a
housing, a gripping portion 9012, a firing actuator 9014, and a
motor positioned within the housing. The surgical instrument 9000
can further comprise a shaft 9040 including a firing rod 9020 which
can be advanced distally and/or retracted proximally by the motor.
In certain circumstances, an end effector can comprise a distal
portion which can articulate relative to a proximal portion about
an articulation joint. In other circumstances, an end effector may
not have an articulation joint. The surgical instrument can further
comprise an articulation drive configured to articulate at least a
portion of the end effector. Referring again to the exemplary
embodiment depicted in FIG. 94, for example, the surgical
instrument 9000 can comprise an articulation actuator 9070 which
can be configured to drive a distal portion of an end effector
about an articulation joint. The end effector depicted in FIG. 94,
i.e., end effector 9060, does not happen to be an articulatable end
effector; however, an articulatable end effector could be utilized
with the surgical instrument 9000. In the event that a
non-articulatable end effector, such as the end effector 9060, for
example, is used with the surgical instrument 9000, the operation
of the articulation actuator 9070 may not affect the operation of
the end effector 9060.
[0369] Further to the above, an end effector can include drive
systems which correspond to the drive systems of the surgical
instrument. For instance, the end effector 9060 can include a
firing member which can be operably engaged with the firing rod
9020 of the surgical instrument 9000 when the end effector 9060 is
assembled to the surgical instrument. Similarly, an end effector
can comprise an articulation driver which can be operably engaged
with an articulation rod of the surgical instrument when the end
effector is assembled to the surgical instrument. Furthermore, the
end effector 9060, for example, can comprise a proximal connection
portion 9069 which can be mounted to a distal connection portion
9042 of the shaft 9040 of the surgical instrument 9000 when the end
effector 9060 is attached to the surgical instrument 9000. In
various circumstances, the proper assembly of the connection
portions, the drive system, and the articulation system of an end
effector and a surgical instrument may be required before the end
effector can be properly used.
[0370] Referring again to FIG. 94, the handle 9010 can comprise a
firing trigger 9014 which, when actuated by the user of the
surgical instrument 9000, can be configured to operate the motor in
the handle 9010. In various circumstances, the handle 9010 can
include a controller which can be configured to detect the
actuation of the firing trigger 9014. In some instances, the
actuation of the firing trigger 9014 can close an electrical
circuit in signal communication with the controller. In such
instances, the controller can be configured to then operate the
motor to advance the firing rod 9020 distally and move a jaw 9062
of the end effector 9060 toward a jaw 9064. In some circumstances,
the handle 9010 can include at least one sensor which can be
configured to detect the force applied to the firing trigger 9014
and/or the degree to which the firing trigger 9014 is moved. The
sensor, or sensors, can be in signal communication with the
controller, wherein the controller can be configured to adjust the
speed of the motor based on one or more input signals from the
sensors. The handle 9010 can comprise a safety switch 9015 which
may need to be depressed before the controller will operate the
motor in response to input from the firing trigger 9014. In various
circumstances, the safety switch 9015 can be in signal
communication with the controller wherein the controller can
electronically lockout the use of the motor until the safety switch
9015 is depressed. The handle 9010 may also comprise a retraction
actuator 9074 which, when actuated, can cause the motor to be
operated in an opposite direction to retract the firing rod 9020
and permit the jaw 9062 to move away from the jaw 9064. In various
circumstances, the actuation of the retraction actuator 9074 can
close an electrical circuit in signal communication with the
controller. In some instances, the safety switch 9015 may need to
be depressed before the controller will operate the motor in its
reverse direction in response to input from the retraction actuator
9074.
[0371] Prior to and/or during the use of the surgical instrument
9000, the surgical instrument 9000 and/or certain systems of the
surgical instrument 9000 may become inoperative, maloperative,
and/or defective. In certain circumstances, such deficiencies,
and/or the manner by which to resolve them, may not be readily
apparent to the user of the surgical instrument which can cause the
user to become frustrated. Moreover, such uncertainties can
increase the time needed to address the deficiency, or "error". The
surgical instrument 9000 is an improvement over the foregoing.
Referring again to FIG. 94, the controller of the surgical
instrument 9000 can be configured to detect an error of the
surgical instrument 9000 and communicate that error to the user of
the surgical instrument 9000 via one or more indicators. The
surgical instrument 9000 can comprise one or more indicators which,
when activated by the controller, can indicate the nature of the
error and/or otherwise direct their attention to the system of the
surgical instrument 9000 that is deficient in some way. For
instance, the surgical instrument 9000 can comprise an end effector
indicator 9086 which can be, for example, configured to indicate
that an end effector has not been assembled to the shaft 9040 of
the surgical instrument 9010. In various circumstances, the
surgical instrument 9000 can comprise a sensor which can be
configured to detect when an end effector has been assembled to the
shaft 9040 and/or, correspondingly, when an end effector has not
been assembled to the shaft 9040. The sensor can be in signal
communication with the controller such that the controller can
receive a signal from the sensor and ascertain whether or not an
end effector has been assembled to the shaft 9040. In the event
that the controller ascertains that an end effector has not been
assembled to the shaft 9040, the controller can actuate the end
effector indicator 9086. In various circumstances, the end effector
indicator 9086 can comprise a light, such as a red light, for
example. In some circumstances, the end effector indicator 9086 can
comprise a light emitting diode, such as a red light emitting
diode, for example. In addition to or in lieu of the above, the
surgical instrument 9000 can comprise a sensor in signal
communication with the controller which can be configured to detect
when the end effector attached to the shaft 9040 has been
previously used. For instance, such a sensor could be configured to
ascertain that at least some of the staples stored within the end
effector have been fired and/or that a staple firing member within
the end effector has been previously advanced. In such instances,
the controller can actuate the end effector indicator 9086. Thus,
the activation of the end effector indicator 9086 can signal to the
user of the surgical instrument 9000 that some error exists with
regard to the end effector and that such error should be, or must
be, addressed prior to operating the surgical instrument 9000. The
reader will appreciate from FIG. 94 that the end effector indicator
9086 is adjacent to the distal end of the shaft 9040 and, in
various circumstances, can be located on, or near, the distal
connection portion 9042 of the shaft 9040. In various
circumstances, the end effector indicator 9086 could be located on
the end effector 9060. In any event, when the end effector
indicator 9086 is illuminated, as a result of the above, the user
of the surgical instrument 9000 can quickly ascertain that an error
exists and that error pertains to the end effector in some way. The
illumination of the end effector indicator 9086 can indicate to the
user that the assembly of the end effector to the shaft 9040 may be
incomplete and/or that the end effector may need to be
replaced.
[0372] In addition to or in lieu of the end effector indicator
9086, a surgical instrument can comprise one or more indicators.
For instance, the surgical instrument 9000 can comprise a firing
trigger indicator 9081. The firing trigger indicator 9081 can be in
signal communication with the controller of the surgical instrument
9000 such that, when the controller detects an error related to the
firing drive of the surgical instrument 9000, for example, the
controller can activate the firing trigger indicator 9081. As
illustrated in FIG. 94, the firing trigger indicator 9081 can be
positioned adjacent to the firing trigger 9014. In such
circumstances, the user of the surgical instrument 9000, upon
observing the actuation of the firing trigger indicator 9081, may
deduce that an error has occurred related to the firing drive and
may begin to diagnose the source of the error. In some
circumstances, the controller may activate the firing trigger
indicator 9081 when the battery of the surgical instrument 9000 has
become defective in some way, for example. For instance, if the
voltage of the battery is below a desirable level, the battery may
not be able to operate the motor in a desired manner and the firing
trigger indicator 9081 may indicate the need to replace the
battery, for example. In various circumstances, the controller can
currently render one or more operating systems of the surgical
instrument 9000 inoperative when the controller illuminates an
indicator, such as the end effector indicator 9086 and/or the
firing trigger indicator 9081, for example. For instance, the
controller can be configured to operably decouple the firing
trigger 9014 from the motor such that the actuation of the firing
trigger 9014 does not operate the motor when the end effector
indicator 9086 and/or the firing trigger indicator 9081 is
illuminated, for example. Such an operative decoupling of the
firing trigger 9014 from the motor can also indicate to the user of
the surgical instrument 9000 that the surgical instrument may have
experienced an error and that the user should review the indicators
of the surgical instrument 9000 to ascertain the nature of that
error.
[0373] Referring again to the exemplary embodiment of FIG. 94, the
surgical instrument 9000 can comprise a retraction actuator
indicator 9085 positioned adjacent to the retraction actuator 9074.
Similar to the above, the retraction actuator indicator 9085 can be
in signal communication with the controller wherein, in the event
the controller detects an error in connection with the retraction
drive, for example, the controller can illuminate the retraction
actuator indicator 9085. In various circumstances, the controller
can illuminate the retraction actuator indicator 9085 in the event
that the safety switch 9015 is not depressed prior to actuating the
retraction actuator 9074. In such circumstances, the retraction
actuator indicator 9085 can serve as a reminder to depress the
safety switch 9015. In certain circumstances, the surgical
instrument 9000 can comprise a safety switch indicator 9082
positioned adjacent to the safety switch 9015. In some
circumstances, the controller of the surgical instrument 9000 can
illuminate the safety switch indicator 9082 when the user actuates
the retraction actuator 9074 before actuating the safety switch
9015. The safety switch indicator 9082 can be in signal
communication with the controller wherein, in the event that the
controller detects that the firing system cannot be switched
between a firing mode and a retraction mode, for example, the
controller can illuminate the safety switch indicator 9082. The
surgical instrument 9000 can comprise an articulation actuator
indicator 9084 positioned adjacent to the articulation actuator
9070. Similar to the above, the articulation actuator indicator
9084 can be in signal communication with the controller wherein, in
the event the controller detects an error in connection with the
articulation drive, for example, the controller can illuminate the
articulation actuator indicator 9084. The surgical instrument 9000
can comprise a shaft indicator 9083 positioned adjacent to a shaft
connection configured to attach the shaft 9040 to the handle 9010.
Similar to the above, the shaft indicator 9083 can be in signal
communication with the controller wherein, in the event the
controller detects an error in connection with the shaft 9040, for
example, the controller can illuminate the shaft indicator
9083.
[0374] Turning now to FIG. 95, a surgical instrument 9100 can
include a handle 9110 including an array of indicators 9190
configured and operated to indicate to the user of the surgical
instrument 9100 that one or more errors may exist with regard to
the surgical instrument 9100 and/or the end effector attached
thereto. The array of indicators 9190 can be arranged in any
suitable manner. In various circumstances, the array of indicators
9190 can be arranged in the shape of, or the approximate shape of,
the surgical instrument 9100 and/or an end effector attached
thereto, for example. In at least one instance, the outer surface
of the handle 9110, for example, can include a representation of
the surgical instrument 9100 and/or the end effector attached to
the surgical instrument. The array of indicators 9190 can be
arranged relative to an outline of the surgical instrument and the
end effector in a manner configured to convey the portion of the
surgical instrument 9100 and/or end effector which is experiencing
an error, has experienced an error, and/or may need to be evaluated
to address an error, for example. For instance, the outline can be
demarcated to depict the end effector 9060, the shaft 9040, the
handle 9010, the firing trigger 9014, the safety switch 9015, the
reverse actuator 9074, and/or the articulation actuator 9070. In
various circumstances, an end effector indicator 9192 can be
positioned adjacent the depiction of the end effector 9060, a shaft
indicator 9193 can be positioned adjacent the depiction of the
shaft 9040, a firing trigger indicator 9191 can be positioned
adjacent the depiction of the firing trigger 9014, a safety switch
indicator 9195 can be positioned adjacent the depiction of the
safety switch 9015, a reverse actuator indicator 9196 can be
positioned adjacent the depiction of the reverse actuator 9074,
and/or an articulation actuator indicator 9194 can be positioned
adjacent the depiction of the articulation actuator 9070, for
example. In various circumstances, each of the indicators 9191,
9192, 9193, 9194, 9195, and/or 9196 can comprise a light emitting
diode. In some circumstances, each light emitting diode can
comprise a red light emitting diode which can be illuminated by the
controller to indicate the presence of an error. In various
circumstances, the controller can be configured to pulse the
illumination of a light emitting diode which may decrease the time
needed for the user to realize that an indicator has been
illuminated. In certain circumstances, each indicator can include a
light emitting diode which can emit more than one color. In some
circumstances, each such light emitting diode can be configured to
selectively emit a red color and a green color, for example. The
controller can be configured to illuminate the light emitting diode
with the green color if no error is not detected with regard to the
associated portion of the surgical instrument 9100 and/or end
effector attached thereto or, alternatively, with the red color if
an error is detected with regard to the associated portion of the
surgical instrument 9100 and/or the end effector attached
thereto.
[0375] In some circumstances, as described in greater detail
further below, the controller of the surgical instrument 9000 can
lock out one or more of the actuators of the surgical instrument,
such as firing trigger 9014, retraction actuator 9074, and/or
articulation actuator 9070, for example, when the controller
illuminates an indicator associated with that actuator. For
instance, the controller can lock out the firing trigger 9014 when
it illuminates the firing trigger indicator 9081, the retraction
actuator 9074 when it illuminates the retraction actuator indicator
9085, and/or the articulation actuator 9070 when it illuminates the
articulation actuator indicator 9084. The handle 9010 of the
surgical instrument 9000, for example, can comprise a firing
trigger lock which can be configured to selectively `lock out` the
firing trigger 9014 and prevent the firing trigger 9014 from being
actuated. The firing trigger lock can prevent the firing trigger
9014 from being sufficiently actuated to operate the motor of the
surgical instrument. In at least one such circumstance, the firing
trigger 9014 can be prevented from closing a firing trigger switch.
In certain circumstances, the controller of the surgical instrument
9000 can be configured such that it electronically locks out the
firing trigger 9014, i.e., prevents battery power from being
supplied to the motor, in addition to actuating the firing trigger
lock. In such circumstances, the electronic lock out and the
mechanical lock out may be redundant; however, the mechanical lock
out can provide feedback to the user of the surgical instrument
9000 that the firing drive has been operably deactivated. As
mentioned above, the controller of the surgical instrument 9000 can
also provide feedback via the firing trigger indicator 9081, for
example. In such a way, a user of the surgical instrument 9000 can
be provided with tactile feedback and/or visual feedback that an
error has occurred. In some circumstances, the tactile feedback may
prompt the user of the surgical instrument 9000 to begin searching
for the visual feedback. For instance, the user may attempt to
actuate the firing trigger 9014 and, upon being unable to actuate
the firing trigger 9014, the user may then review the instrument
for illuminated indicators. In any event, once the error has been
resolved, the controller can unlock the firing trigger 9014 by
deactivating the firing trigger lock.
[0376] Turning now to FIG. 100, the surgical instrument 9000 can
include a firing trigger lock 9390 which can be configured to lock
out the firing trigger 9014. The firing trigger lock 9390 can be
movable between a locked condition, illustrated in FIGS. 100, 101,
and 103, and an unlocked condition, illustrated in FIG. 102. When
an end effector is not assembled to the shaft 9040 of the surgical
instrument 9000, the firing trigger lock 9390 can be biased into
its locked condition. In this locked condition, the firing trigger
lock 9330 can block, or at least substantially block, the actuation
of the firing trigger 9014. More particularly, the firing trigger
lock 9390 can include a shaft rack 9391, a pinion 9392, and a
handle rack 9393, and a biasing member, such as a spring, for
example, which can be configured to bias the shaft rack 9391 into a
proximal position and the handle rack 9393 into a downward
position. The proximal position of the shaft rack 9391 and the
downward position of the handle rack 9393 are illustrated in FIG.
101. Referring primarily to FIG. 101, the handle rack 9393 can
include apertures 9396 and the firing trigger 9014 can include
projections 9395 which, when the handle rack is in its downward
position, are not aligned with the apertures 9396. More
specifically, the firing trigger 9014 can comprise a rocker switch
including a fulcrum 9397 wherein, when the handle rack 9393 is in
its downward position, rocking of the firing trigger 9014 will
cause at least one of the projections 9395 extending from the
firing trigger 9014 to abut the handle rack 9393 and prevent the
firing trigger 9014 from being completely actuated.
[0377] When an end effector is attached to the shaft 9040, further
to the above, the firing trigger lock 9390 can be moved between its
locked configuration and its unlocked configuration. In the
unlocked configuration of the firing trigger lock 9390, referring
primarily to FIG. 102, the handle rack 9393 can be in its upward
position. In the upward position of the handle rack 9393, the
apertures 9396 defined in the handle rack 9393 are aligned with the
projections 9395 extending from the firing trigger 9014. In such
circumstances, the firing trigger 9014 can be rocked to actuate the
firing trigger 9014. More specifically, the projections 9395 can
pass through the apertures 9396 to permit the rocking of the firing
trigger 9014 about the fulcrum 9397. Thus, in view of the above,
the movement of the handle rack 9393 between its downward and
upward positions respectively locks and unlocks the firing trigger
9014. Various mechanisms can be utilized to move the handle rack
9393 between its downward position and its upward position. In at
least one such embodiment, referring again to FIG. 100, the shaft
9040 can include a firing lock actuator 9399 which can be displaced
proximally by an end effector when the end effector is assembled to
the shaft 9040. The shaft rack 9391 can be mounted and/or extend
proximally from the firing lock actuator 9399 and can include teeth
9391a defined thereon. The teeth 9391a can be meshingly engaged
with teeth 9392a defined on pinion gear 9392 such that, when the
firing lock actuator 9399 and the shaft rack 9391 are displaced
proximally, the pinion gear 9392 can be rotated about an axis.
Correspondingly, the handle rack 9393 can comprise rack teeth 9393a
defined thereon which are also meshingly engaged with the pinion
gear teeth 9392a and, thus, when the shaft rack 9391 is driven
proximally, the handle rack 9393 can be driven from its downward
position into its upward position thereby unlocking the firing
trigger 9014. In order to return the handle rack 9393 to its
downward position, the shaft rack 9391 can be moved distally to
rotate the pinion gear 9392 in the opposite direction. In various
circumstances, the shaft rack 9391 can move distally as a result of
an end effector being disassembled from the shaft 9040.
[0378] Turning now to FIGS. 96-97, handle 9010, for example, can
include a trigger lock 9290. The trigger lock 9290 can comprise a
housing 9291, a deployable lock pin 9292, a retainer 9293, and a
biasing member 9294 configured to move the lock pin 9294 between an
undeployed position, illustrated in FIGS. 96 and 98 and a deployed
position, illustrated in FIGS. 97 and 99. In various instances, the
retainer 9293 can be comprised of a temperature sensitive material
which is affected by heat. In at least one such instance, the
temperature sensitive material can be configured to transition
between a solid and a fluid, such as a liquid, suspension, and/or
gas, for example, and/or between a solid material and semi-solid
material, for example. When the temperature sensitive material
transitions, or at least partially transitions, between a solid and
a fluid, the retainer 9293 can release the lock pin 9294 to lock
the firing trigger, and/or any other suitable trigger, of the
handle 9010. In various instances, the lock pin 9294, when
deployed, can slide behind and/or otherwise engage the firing
trigger. A handle can include any suitable number of trigger locks
9290, or the like, to selectively lock out any suitable number of
triggers and/or buttons, for example. As the reader will
appreciate, the trigger lock 9290 may not be resettable. In such
instances, an actuated trigger lock 9290 may permanently lock out
the firing trigger, for example, of the handle such that the
instrument may no longer be used. A permanent lock out of the
firing trigger, and/or any other trigger, of the instrument may
mean that the instrument may no longer be usable whatsoever while,
in other circumstances, the permanent lock out may not be readily
resettable and may require the instrument to be sent to a qualified
technician, or facility, for example, who can assess whether the
instrument should be reconditioned and reused or whether the
instrument should be disposed of. When the heat sensitive material
of the retainer 9293 has been at least partially converted to a
fluid, it may be assumed by the technician that the instrument was
exposed to a temperature which exceeded the transition temperature
of the heat sensitive material. In various instances, the
transition temperature of the heat sensitive material can be the
temperature in which the solid material, for example, liquefies,
evaporates, and/or sublimates, for instance. In any event, the heat
sensitive material, and, hence, the transition temperature, of the
retainer 9293 can be selected such that the release of the lock pin
9294 can indicate that the surgical instrument has been exposed to
a temperature which exceeds a certain, or threshold, temperature.
In various instances, a surgical instrument can be damaged if it is
exposed to an excessive temperature. For instance, the surgical
instrument can include solid state electronics, for example, which
can be damaged when exposed to such an excessive temperature. In
such instances, the threshold temperature of the instrument and the
transition temperature of the retainer 9293 can be equal, or at
least substantially equal, wherein, as a result, it can be assumed
that the instrument has not been exposed to a temperature which
exceeds the threshold temperature when the trigger lock 9290 has
not been actuated and, correspondingly, that the instrument has
been exposed to a temperature which exceeds the threshold
temperature when the trigger lock 9290 has been actuated and, as
such, the surgical instrument may have been damaged, or may at
least require an evaluation as to whether it has been damaged.
[0379] Further to the above, a surgical instrument may be exposed
to temperatures which exceed the threshold temperature and/or the
transition temperature when the surgical instrument is sterilized.
Many sterilization procedures are known, several of which include
the step of exposing the surgical instrument to heat. In addition
to or in lieu of the trigger lock 3290, a surgical instrument can
include at least one temperature sensor which can evaluate the
temperature in which the surgical instrument is exposed to. In
various instances, the temperature sensor, or sensors, can be in
signal communication with a controller of the surgical instrument
which can be configured to assess whether the surgical instrument
has been exposed to a temperature which exceeds the threshold
temperature. In at least one such instance, the controller can
include a microprocessor and an algorithm which can evaluate the
signals received from the temperature sensor, or sensors. In the
event that the controller determines that the threshold temperature
has been reached and/or exceeded, the controller can permanently
prevent the instrument from being operated. Stated another way, the
controller can apply an electronic lock out to the surgical
instrument. Similar to the above, a permanent lock out of the
instrument may mean that the instrument may no longer be usable
whatsoever while, in other circumstances, the permanent lock out
may not be readily resettable and may require the instrument to be
sent to a qualified technician, or facility, for example, who can
assess whether the instrument should be reconditioned and reused or
whether the instrument should be disposed of. As the reader will
appreciate, a power source may be needed to operate the controller
and/or sensors of the surgical instrument while the surgical
instrument is being sterilized. Several embodiments of surgical
instruments include a removable battery, or power source, which is
removed prior to sterilizing the surgical instrument wherein, in
such instances, the removable battery is sterilized and/or
reprocessed separately. Once the removable power source has been
removed from these previous instruments, as the reader will
appreciate, the controller and/or sensors may not have sufficient
power to monitor the temperature of the surgical instrument.
Embodiments of surgical instruments disclosed herein can include a
battery, or power source, which is not removed from the surgical
instrument when it is reprocessed. Such a battery may be referred
to as a permanent battery as it may supply power to the controller
and/or temperature sensors while the instrument is being
sterilized. In various instances, an instrument including a
permanent battery may also include a removable and/or rechargeable
battery. In any event, the instrument may have sufficient power to
detect and record the temperature that the instrument is exposed
to. In at least one instance, the controller of the instrument can
include a memory chip configured to store the temperature readings,
such as in a temperature register, for instance. In various
circumstances, the controller can record readings from the sensors
intermittently, i.e., at an appropriate sampling rate. In some
instances, the controller can be configured such that, when it
records a temperature reading above a certain temperature, albeit
below the threshold temperature, the controller can increase the
sampling rate. Correspondingly, the controller can be configured
such that, when it subsequently records a temperature reading below
the certain temperature, the controller can decrease the sampling
rate, such as back to its original sampling rate, for instance.
[0380] Turning now to FIG. 99A, an algorithm for the controller is
depicted. In certain instances, this algorithm can comprise a
start-up procedure for the surgical instrument such as when the
surgical instrument is first used after it has undergone a
sterilization process, for instance. The start-up procedure can
commence after the instrument has been turned on. The instrument
can be automatically turned on when an end effector is assembled to
the instrument. In at least one such instance, the assembly of the
end effector to the surgical instrument can close a switch in
signal communication with the controller. In addition to or in lieu
of the above, the instrument can be turned on when a button and/or
switch is depressed on the handle, for example. In any event, the
controller can then evaluate temperature readings stored in the
memory chip, discussed above. For instance, the controller can
evaluate whether any of the stored temperature readings are equal
to or greater than the threshold temperature. If the controller
determines that all of the stored temperature readings are below
the threshold temperature, the controller can proceed with its
normal startup procedure. If the controller determines that one or
more stored temperature readings are equal to or exceed the
threshold temperature, the controller can proceed with an alternate
procedure. In at least one instance, the controller can permanently
disable the instrument such as by implementing an electronic
lockout and/or a mechanical lockout, as discussed elsewhere in this
application. In certain other instances, the controller can permit
the instrument to be used eventhough the controller has determined
that one or more stored temperature readings is equal to or exceeds
the threshold temperature. The controller can store that
determination in its memory and/or indicate to the user through a
display, such as a light emitting diode, for example, that the
threshold temperature had been previously exceeded and then proceed
with its normal startup procedure. In various instances, the
controller can treat the threshold temperature as an absolute
maximum, i.e., a single temperature reading at or above the
threshold temperature is sufficient to trigger an alternative
startup program or permanently lockout the instrument. In other
instances, the controller can be configured to evaluate whether a
pattern of temperature readings at or above the threshold
temperature is sufficient to trigger an alternative startup program
or permanently lockout the instrument as both time and temperature
may be factors to consider whether an instrument has been
compromised from a sterilization procedure, for example.
[0381] Turning now to FIGS. 104-109, a surgical instrument, such as
the surgical instrument 9000, for example, can include a handle
9410 including a firing trigger lock system 9490. The handle 9410
can be similar to the handle 9110 in many respects and such
respects are not repeated herein for the sake of brevity. Similar
to the above, the firing trigger lock system 9490 can be configured
to lock and unlock a firing trigger 9414. Also similar to the
above, the firing trigger lock system 9490 can be biased into a
locked condition when an end effector is not assembled to the shaft
9040 of the surgical instrument, as illustrated in FIGS. 104-107,
and moved into an unlocked condition when an end effector is fully
assembled to the shaft 9040, as illustrated in FIGS. 108 and 109.
When an end effector is assembled to the shaft 9040, further to the
above, referring primarily to FIGS. 108 and 109, the end effector
can push the sensing member 9499 proximally. The sensing member
9499 can extend through the shaft 9040 from a distal end of the
shaft 9040 to a proximal end thereof. In use, the end effector can
abut the distal end of the sensing member 9499 when the end
effector is assembled to the shaft 9040 and push the sensing member
9499 proximally, as outlined above. When the sensing member 9499 is
pushed proximally, as illustrated in FIGS. 108 and 109, the sensing
member 9499 can contact a swing arm 9486 of the firing trigger lock
system 9490 and rotate the swing arm 9486 upwardly. The swing arm
9486 can comprise an end pivotably mounted to the handle housing
via a pin 9487 which is configured to permit the swing arm 9486 to
rotate about an axis. The swing arm 9486 can further comprise a cam
follower portion 9488 which can be contacted by the sensing member
9499. In use, the sensing member 9499 can move the swing arm 9486
between a downward position and an upward position in order to move
the firing trigger lock system 9490 between a locked position and
an unlocked position, respectively. The firing trigger lock system
9490 can further include a lock pin 9485 mounted to the swing arm
9486 which can be pulled upwardly when the swing arm 9486 is
rotated upwardly and, correspondingly, pushed downwardly when the
swing arm 9486 is rotated downwardly. The lock pin 9485 can
comprise an upper end pivotably mounted to the swing arm 9486 and a
lower end that extends through an aperture 9483 defined in the
firing trigger 9481 when the lock pin 9485 is in its downward
position. In various circumstances, the aperture 9483 can be
defined in an arm 9482 extending from the firing trigger 9414. When
the lock pin 9485 is positioned within the aperture 9483, the
firing trigger 9414 may not be pivoted about its fulcrum 9484 and,
as a result, the firing trigger 9414 may not be actuated by the
user. When the lock pin 9485 is in its upward position, the lock
pin 9485 may not be positioned within the aperture 9483 and, as a
result, the firing trigger 9414 may be actuated by the user. When
the end effector is disassembled from the shaft 9040, the sensing
member 9499 can be moved from its proximal position to its distal
position. Stated another way, without an end effector attached to
the shaft 9040, a biasing member, such as spring 9489, for example,
can bias the swing arm 9486 downwardly and, accordingly, bias the
firing trigger lock system 9490 into its locked condition.
Moreover, the spring 9489 can apply a biasing force to the sensing
member 9499 through the arm 9482 and push the sensing member 9499
distally when an end effector is not assembled to the shaft
9040.
[0382] Further to the above, the operation of the sensing member
9499 and the firing trigger lock system 9490 can serve to
communicate with the user of the surgical instrument. For instance,
when an end effector is not assembled to the shaft 9040, the
sensing member 9499 is biased distally and the firing trigger 9414
will be locked out wherein, if the user were to attempt to actuate
the firing trigger 9414, the user would quickly realize that
something may be wrong with the firing system of the surgical
instrument. In this example, the user would quickly realize that an
end effector needs to be assembled to the shaft 9040 in order to
use the surgical instrument. In various circumstances, the firing
trigger could be locked out if an end effector, although attached
to the shaft 9040, had been used. In at least one such
circumstance, the end effector could include a firing member which,
when positioned in its proximal-most position, could push a sensing
member proximally when the end effector is assembled to the shaft
9040; however, if such a firing member has already been at least
partially advanced when the end effector is assembled to the shaft
9040, the sensing member may not be pushed proximally and, as a
result, the firing trigger may remain locked out. Again, such a
firing trigger lock out can communicate to the user that a problem
exists with the firing drive; namely, in this circumstance, that
the end effector has already been used. Absent such a tactile
lockout, the user would experience circumstances in which they are
able to depress an actuator without the surgical instrument
responding to the depressed actuator thereby possibly leading to
the confusion of the user.
[0383] As discussed above, the assembly of a previously-unfired end
effector to the shaft 9040 can push a sensing member proximally to
unlock the firing trigger. In various circumstances, the sensing
member and the firing trigger lock system can be configured such
that the firing trigger is not unlocked until the end effector is
completely assembled to the shaft 9040. In the event that the end
effector is only partially assembled to the shaft 9040, the sensing
member may not be sufficiently displaced to unlock the firing
trigger. Again, such a firing trigger lockout can communicate to
the user that a problem exists with the firing drive; namely, in
this circumstance, that the end effector has not been completely
assembled to the shaft 9040.
[0384] As described herein, an end effector can be assembled to
surgical instrument which can include a controller configured to
identify the end effector. In some instances, the controller can be
configured to assess the identity of the end effector when the
controller is activated. In certain instances, turning now to FIG.
176, the controller can be activated when a battery is inserted
into the handle. In addition to or in lieu of the above, the
controller can be configured to assess the condition of the
surgical instrument when the controller is activated. For example,
the controller can be configured to assess the position of the
closure member of the closing system, the position of the firing
member of the firing system, and/or the position of the
articulation member of the articulation system. In certain
instances, the surgical instrument can include an absolute
positioning sensor to detect the position of the firing member.
Such a sensor is disclosed in U.S. patent application Ser. No.
13/803,097, entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A
FIRING DRIVE, which was filed on Mar. 14, 2013, the entire
disclosure of which is incorporated by reference herein. In some
instances, the surgical instrument can include an end of stroke
register. Such an end of stroke register can comprise a mechanical
switch, counter, and/or toggle and/or an electronic switch,
counter, and/or toggle including data stored in nonvolatile memory.
In such an embodiment, the controller can assess whether the
previous firing stroke had been completed. Such embodiments can be
helpful in a multitude of situations. For instance, the controller
may be accidentally shut off or otherwise lose power during a
surgical procedure and, when the controller is reactivated, the
controller may not be able to assess whether the instrument is
being initialized for the first time or whether the instrument was
in the middle of a previous firing stroke. The end of stroke
register can assist the controller in discerning between these two
events. Moreover, an end of stroke of register that is not lost or
reset by a power loss or interruption to the instrument can allow
the controller to assess whether the surgical instrument had lost
power during a firing stroke. If the controller determines that the
previous firing stroke had not been completed, the controller can
be configured to, one, permit power to be supplied to the motor to
finish the firing stroke and/or, two, permit power to be supplied
to the motor to retract the firing member, the closure member,
and/or the articulation member to their home, or unactuated,
positions. In various instances, the controller can provide the
user of the surgical instrument with the option of proceeding with
the firing stroke or returning the mechanical systems and/or
electrical systems of the instrument to their original, or
unactuated, positions. In such embodiments, the surgical instrument
may not automatically return these systems to their original, or
unactuated, positions. In any event, once the surgical instrument
is in its home, or unactuated, condition, a previously fired end
effector can be disassembled from the surgical instrument and/or an
unfired end effector can be assembled to the surgical instrument.
In various instances, as outlined herein, the surgical instrument
can then identify, or at least attempt to identify, the unfired end
effector.
[0385] Turning now to FIG. 177, a controller of a surgical
instrument can perform a diagnostic check of the instrument and/or
battery. For instance, upon activation of the controller, the
surgical instrument can evaluate whether the surgical instrument
had been exposed to a temperature beyond the threshold temperature
of the surgical instrument, as described herein. Also, for
instance, the surgical instrument can evaluate the available power,
voltage, and/or current of the battery, as also described herein.
If the instrument fails one or more of these diagnostic tests, the
controller may not supply power to the motor, physically lockout
the instrument, and/or indicate such failure to the user of the
surgical instrument. In such circumstances, the instrument may
record such failures in its memory so that the test data may assist
a technician in later evaluating the instrument. Assuming that the
instrument passes these diagnostic tests, the instrument, similar
to the above, may also record the test data associated with passing
the diagnostic tests. In any event, the instrument may then proceed
to evaluate whether the instrument is in a home, or unactuated,
condition and assess the identity of the end effector. As outlined
herein, a procedure for identifying the end effector is disclosed.
Also disclosed herein is a procedure for assessing whether a
`smart` end effector or a `dumb` end effector is attached to the
surgical instrument. In various instances, a `smart` end effector
can be an end effector which can supply parameters and/or at least
a portion of an operating program to the surgical instrument as
part of the identification process. A `smart` end effector can be
an end effector which somehow identifies the manner in which the
end effector is to be used by the surgical instrument. In certain
instances, a `dumb` end effector is an end effector which does not
identify the manner in which it is to be used with the surgical
instrument in any way. An exemplary operating procedure in
accordance with the above is outlined in FIG. 178.
[0386] As discussed herein, a battery can be utilized to power a
surgical instrument. In various instances, the surgical instrument
and/or battery can be configured to assess whether the battery can
supply sufficient power to the surgical instrument to perform one
or more functions. In certain instances, the surgical instrument
and/or the battery can be configured to indicate to the user of the
surgical instrument that the battery has sufficient power to
perform one or more functions. FIG. 179 depicts a circuit
configured to indicate the voltage of a battery. Such a circuit can
be present in the surgical instrument and/or the battery. In either
event, a circuit can include a plurality of indicators which can be
indicative of the charge, voltage, and/or power that can be
supplied by the battery. For instance, the circuit can include
three indicators including a first indicator configured to indicate
that the battery includes at least a first voltage, a second
indicator configured to indicate that the battery includes at least
a second voltage, and a third indicator configured to indicate that
the battery includes at least a third voltage. As illustrated in
FIG. 179, a circuit 12100 can include a first indicator circuit
12110, a second indicator circuit 12120, and a third indicator
circuit 12130 which are arranged in parallel with one another. When
switch 12101 is closed, a voltage potential from the battery can be
applied across the indicator circuits 12110, 12120, and 12130. The
first indicator circuit 12110 can include a Zener diode 12111, a
light emitting diode 12112, and a resistor R1 12113. Similarly, the
second indicator circuit 12120 can include a Zener diode 12121, a
light emitting diode 12122, and a resistor R2 12123 and the third
indicator circuit 12130 can include a Zener diode 12131, a light
emitting diode 12132, and a resistor R3 12133. The Zener diodes
12111, 12121, and 12131 can each have a different breakdown
voltage. For instance, the first Zener diode 12111 can have a
breakdown voltage of 11.5V, for example, the second Zener diode
12121 can have a breakdown voltage of 10V, for example, and the
third Zener diode 12131 can have a breakdown voltage of 8V, for
example. In such an embodiment, if the voltage of the battery is
greater than or equal to 11.5V, the LEDs 12112, 12122, and 12132
will be illuminated. The illumination of all of the LEDs can
indicate to the user of the surgical instrument that the battery
has a full charge and/or at least a sufficient charge to perform
any function required by the surgical instrument. If the voltage of
the battery is greater than or equal to 10V, but less than 11.5V,
the LEDs 12112 and 12122 will be illuminated; however, LED 12132
will not be illuminated. The illumination of LEDs 12112 and 12122,
but not LED 12132, can indicate to the user of the surgical
instrument that the battery has less than a full charge, but at
least a sufficient charge to perform any function required by the
surgical instrument. If the voltage of the battery is greater than
or equal to 8V, but less than 10V, the LED 12112 will be
illuminated; however, LEDs 12122 and 12132 will not be illuminated.
The illumination of LED 12112, but not LEDs 12122 and 12132, can
indicate to the user of the surgical instrument that the battery is
nearing the end of its charge and may or may not have a sufficient
charge to perform certain functions required by the surgical
instrument. Such a display of the LEDs can indicate that the
battery may need to be replaced. If the voltage of the battery is
less than 8V, none of the LEDs 12112, 12122, and 12132 will be
illuminated. Such a display of the LEDs can indicate that the
battery may not be usable to reliably perform any function of the
surgical instrument. While circuit 12100 utilizes three indicator
circuits 12110, 12120, and 12130, a circuit can include more than
three indicator circuits having Zener diodes with different
breakdown voltages. Such an embodiment can provide a more finely
graduated indication of the voltage of the battery, for instance.
Other embodiments are envisioned which utilize only two indicator
circuits.
[0387] In various instances, a battery can include a circuit
configured to indicate that the battery is charged and/or has a
charge sufficient enough that it can be used with a surgical
instrument. In certain instances, a surgical instrument can include
a circuit configured to indicate that a battery attached thereto is
charged and/or has a charge sufficient enough that it can be used
with the surgical instrument. In either event, turning now to FIG.
180, a circuit 12200 can include a microprocessor 12201 which
includes one or more gates in communication with the battery, which
can be a 9V battery, for example. The circuit 12200 can further
comprise a capacitor 12202, such as a 10 microFarad capacitor, for
example, which can receive power from a circuit including diode
12203 and resistor 12204. The circuit 12200 can further comprise a
LED 12205 and a resistor 12206 in the discharge path of capacitor
12202. Such a circuit can cause the LED 12205 to pulse
intermittently so long as the battery can supply sufficient power
to the circuit 12200. In such instances, a user could identify the
pulsing LED 12205 and would know that the battery had at least some
power, if not sufficient power, to be used with the surgical
instrument. If the user does not identify that the LED 12205 is
pulsing, the user can assume that the battery lacks sufficient
power to be used.
[0388] In various circumstances, as discussed herein and referring
to FIG. 284, a battery and/or a surgical instrument configured to
be used with the battery can include a diagnostic circuit
configured to evaluate the power, voltage, and/or current that the
battery can supply. Turning now to FIG. 184, a battery diagnostic
circuit 12300 is disclosed. Such a circuit can be configured to
evaluate the battery before it has been used with a surgical
instrument, while it is being used with a surgical instrument,
and/or after it has been used with a surgical instrument. In
various instances, the battery can be used more than once and, in
various instances, the battery may be rechargeable or
non-rechargeable. The uses of the battery, and the information
obtained during the diagnostic evaluation of the battery, can be
stored in a memory chip in the battery and/or the surgical
instrument. FIG. 183 depicts a table of information 12400 which is
representative of the type of information that could be recorded on
the memory chip. For instance, the number of uses can be recorded.
For each use, the maximum voltage and/or the maximum current that
the battery is charged with, or re-charged with, can be recorded,
for instance. For each use, the current capacity, the current used
in mA, the current used in Ah, and/or the minimum voltage
experienced during use can be recorded, for instance. For each use,
the time in which the battery is charged, the time in which the
battery is used, the temperature of the battery while being
charged, and/or the temperature of the battery while being used can
be recorded, for instance. These are merely a few examples of the
information that can be stored. In various instances, such
information can be utilized by the surgical instrument and/or a
technician to evaluate the previous performance of the battery
and/or the suitability of the battery for further use, for
example.
[0389] In various instances, turning now to FIG. 182, a battery
and/or a surgical instrument used with the battery can include a
circuit for turning off the battery once the charge of the battery
has fallen below a minimum charge level. In some instances, a
lithium ion battery cell may have a thermal incident if it is used
below the minimum charge level and a shut-off circuit inhibiting
the use of the battery below this minimum charge level may inhibit
such a thermal incident from occurring.
[0390] In various instances, turning now to FIG. 181, a surgical
instrument can include a controller configured to perform a
diagnostic check of the instrument and/or the battery assembled
thereto. For instance, the controller can include a clock and a
memory chip configured to evaluate and record when the instrument
and/or battery has been used. In certain instances, the controller
can be configured to disable the instrument and/or battery if it
has been too long since the last time that the instrument and/or
battery had been used. In certain instances, the instrument and/or
battery can include one or more sensors which can be configured to
evaluate various conditions of the instrument and/or battery, such
as the temperature, the humidity, and/or the time in which the
instrument and/or battery are exposed to the temperature and/or
humidity, for example. The controller can be configured to evaluate
whether the sensors are operating correctly and, if not, the
controller can disable the instrument and/or battery. The
controller can also be configured to evaluate the number of times
that the instrument and/or battery have been used and, if the uses
exceed a certain amount, disable the instrument and/or battery. The
controller can also be configured to evaluate the power that the
battery can supply, as outlined herein, and, if the available power
is insufficient, disable the instrument and/or battery.
[0391] As described herein, a surgical instrument can include
various sensors for gathering feedback and/or other instrument
status information. Furthermore, the surgical instrument can
include sensory indicators for providing feedback and/or instrument
status information to the user. In certain instances, an endoscope
can be used in connection with the surgical instrument to provide
additional feedback and/or instrument status information to the
user. As described herein, the endoscope and the surgical
instrument can be in signal communication with a display, which can
depict the feedback from the endoscope and/or from the sensors of
the surgical instrument, for example. Referring now to FIGS. 75-93,
an endoscope 5018 (FIG. 93) can be in signal communication with a
display 5002 (FIG. 75). In certain embodiments, the display 5002
can comprise a heads-up display (HUD) and/or a video monitor, for
example. Furthermore, the display 5002 can be a plasma screen, an
LCD screen, or an electroluminescent screen, for example. In
various embodiments, the display 5002 can broadcast a first layer
of information 5010, which can include video feedback, for example.
The video feedback can be feedback of images viewed by an endoscope
5018 (FIG. 93) at a surgical site, for example, and can depict at
least a portion of a surgical instrument 5020 as viewed by the
endoscope 5018, for example.
[0392] In various embodiments, the display 5002 can include a touch
screen 5004. Referring primarily to FIG. 75, a user can interact
with the touch screen 5004 to interface with the display 5002
and/or the surgical instrument 5020. For example, the touch screen
5004 can communicate with the display 5002, and inputs to the touch
screen 5004 can adjust and/or modify the information depicted on
the display 5002. In such embodiments, the user can communicate
with the display 5002 without utilizing an additional input to the
display, such as a keyboard and/or computer mouse, for example. In
other words, additional input tools and/or parts may not be
required to adjust and/or modify the information depicted on the
display 5002. Furthermore, in various embodiments, the touch screen
5004 can be easily cleaned and/or sterilized. For example, the
touch screen 5004 can include a flat surface that can be easily
wiped clean within a surgical suite and/or operating room.
Additionally or alternatively, the touch screen 5004 can directly
and/or indirectly communicate with the surgical instrument 5020,
such that input to the touch screen 5004 provides input to the
surgical instrument 5020. The user may be a surgeon, operator,
and/or assistant, for example.
[0393] In various embodiments, the touch screen 5004 can be
positioned over at least a portion of the display 5002, and may be
removably secured to the display 5002, for example. For example,
the touch screen 5004 can be compatible with multiple displays, and
can be releasably attached and unattached from at least one
display. Furthermore, in certain embodiments, the touch screen 5004
can be an independent display, which can operate independently of
the display 5002. For example, a detachable LCD screen can comprise
the touch screen 5004, and the detachable LCD screen can overlay at
least a portion of the display 5002. In other embodiments, the
touch screen 5004 can be integrated into the display 5002. The
touch screen 5004 can utilize resistive technology, capacitive
technology, ultrasonic sound beam technology, and/or near field
imaging technology, for example.
[0394] Referring primarily to FIG. 93, in various embodiments, a
feedback controller 5016 can be in signal communication with the
surgical instrument 5020, the endoscope 5018, and/or the display
5002. In certain embodiments, a wired and/or wireless connection
5017 between the feedback controller 5016 and the endoscope 5018
can provide video feedback from the endoscope 5018 to the feedback
controller 5016. Furthermore, a wired and/or wireless connection
5019 between the feedback controller 5016 and the surgical
instrument 5020 and/or the microcontroller of the surgical
instrument 5020 can provide the feedback data measured and/or
detected by the surgical instrument 5020 to the feedback controller
5016. For example, various sensors are described herein, as well as
in Zemlock '263 and Zemlock '344, the entire disclosures of which
have been incorporated herein, and the various sensors can detect
feedback and/or instrument status information. Additionally, a
wired and/or wireless connection 5015 between the feedback
controller 5016 and the display 5002 can provide the feedback data
from the surgical instrument 5020 and/or the video feedback from
the endoscope 5018 to the display 5002. In at least one embodiment,
the video feedback can be depicted in the first layer of
information 5010 on the display 5002, and the feedback data can be
depicted in a second layer of information 5012 on the display 5004.
In embodiments where a detachable LCD display comprising the touch
screen 5004 is positioned over the display 5002, a wired and/or
wireless connection between the feedback controller 5016 and the
detachable LCD display can provide the feedback data to the
detachable LCD display and/or from the LCD display to the feedback
controller 5010, for example.
[0395] Referring primarily to FIG. 76, the display 5002 can
broadcast the first layer of information 5010, which can comprise
the video feedback from the endoscope 5018 (FIG. 93), for example.
In various instances, the video feedback 5010 can include a
depiction of the surgical instrument 5020 affecting tissue T. In
various embodiments, surgical instrument 5020 can be similar to
surgical instrument 10 (FIG. 1), for example, and the disposable
loading unit (DLU) and/or an end effector 5022 coupled to the
surgical instrument can be similar to loading unit 20 (FIG. 2), for
example. The DLU 5022 of the surgical instrument 5020 can
articulate relative to the tissue T, grasp and/or clamp the tissue
T between a pair of jaws, staple the tissue T, and/or cut the
tissue T with a cutting element, as described herein. Furthermore,
the endoscope 5018, which can be positioned at and/or near the
surgical site, can view the DLU 5022 and can transmit the video
feed and/or recording to the feedback controller 5016 (FIG. 93). In
various embodiments, the video feedback in the first layer of
information 5010 on the display 5002 can provide live, visual
feedback of the surgical site to the operator of the surgical
instrument 5020.
[0396] Referring primarily to FIG. 77, the display 5002 can display
a second layer of information 5012. Furthermore, a user can select,
move, resize, minimize, expand, modify, and/or otherwise manipulate
the second layer of information 5012. For example, the user can
manipulate the second layer of information 5012 by interfacing with
the touch screen 5004. As described herein, the second layer of
information 5012 can include feedback data from the surgical
instrument 5020 and/or controls for controlling the surgical
instrument 5020. In various embodiments, the second layer of
information 5012 can include a control panel 5030, and the touch
screen 5004 can be used to select and/or utilize features of the
control panel 5030. The control panel 5030 can be collapsible,
resizable, moveable, and/or otherwise manipulatable by way of the
touch screen 5004. For example, a user can minimize or collapse the
control panel 5030 by selecting the minimize/maximize icon 5032,
and can maximize or un-collapse the control panel 5030 by
re-selecting the minimize/maximize icon 5032. Furthermore, a user
can move the control panel 5030 on the display 5002 by "dragging
and dropping" the control panel 5030 across the display 5002, for
example. Additionally, a user can resize the control panel 5030
relative to the display 5002 by "zooming in" and/or "zooming out"
multiple contact points on the touch screen 5004. A person having
ordinary skill in the art will appreciate that various conventional
and/or intuitive contacts to the touch screen 5004 can be utilized
to modify and/or manipulate the second layer of information 5012
and/or the control panel 5030 thereof, for example.
[0397] Referring still to FIG. 77, the control panel 5030 can
include a plurality of menus, categories, and/or classifications.
For example, the control panel 5030 can include an instrument
feedback menu 5036, a display menu 5060, and/or an instrument
controller menu 5070. A user can utilize the control panel 5030 to
select a menu and/or to switch between operational states of the
touch screen 5004. For example, the touch screen 5004 can
communicate directives and/or controls to the instrument controller
5016 (FIG. 93) and/or the microcontroller when a user selects the
instrument controller menu 5070 of the control panel 5030. In such
embodiments, as described herein, the touch screen 5004 may operate
in an instrument-control state. Furthermore, the settings related
to the secondary layer of information 5012 and/or the display 5002,
for example, can be modified by a user when the display menu 5060
is selected from the control panel 5030. In such embodiments, the
touch screen 5004 may operate in a setting-modification state.
Additionally or alternatively, the feedback data included in the
secondary layer of information 5012 can be modified by a user when
the instrument feedback menu 5036 is selected. In such embodiments,
the touch screen 5004 may operate in a feedback-manipulation state.
In various embodiments, the control panel 5030 can include
additional and/or fewer menus, categories, and/or classifications.
Furthermore, the various menus, categories, and/or classifications
of the control panel 5030 can be modified according to the user's
preferences, for example. The menus, categories, and/or
classifications can be verbally and/or symbolically indicated in
the second layer of information 5012. In various embodiments, the
categories under each menu 5036, 5060, 5070 may be selectively
depicted in the second layer of information 5012. For example, the
categories under each menu 5036, 5060, 5070 may only be depicted in
the second layer of information 5012 when the respective overlying
menu 5036, 5060, 5070 is selected by the user. In other
embodiments, the user can manually minimize and/or maximize
categories and/or subcategories corresponding to each menu 5036,
5060, and/or 5070, for example.
[0398] Still referring to FIG. 77, the instrument feedback menu
5036 can include a plurality of feedback categories, and can relate
to the feedback data measured and/or detected by the surgical
instrument 5020 (FIG. 93) during a surgical procedure. As described
herein, the surgical instrument 5020 can detect and/or measure the
position of a moveable jaw between an open orientation and a closed
orientation, the thickness of clamped tissue, the clamping force on
the clamped tissue, the articulation of the DLU 5022, and/or the
position, velocity, and/or force of the firing element, for
example. Furthermore, the feedback controller 5016 (FIG. 93) in
signal communication with the surgical instrument 5020 can provide
the sensed feedback to the display 5002, which can display the
feedback in the second layer of information 5012. As described
herein, the selection, placement, and/or form of the feedback data
displayed in the second layer of information 5012 can be modified
based on the user's input to the touch screen 5004, for
example.
[0399] In various embodiments, the display menu 5060 of the control
panel 5030 can relate to a plurality of categories, such as unit
systems 5062 and/or data modes 5064, for example. In certain
embodiments, a user can select the unit systems category 5062 to
switch between unit systems, such as between metric and U.S.
customary units, for example. Additionally, a user can select the
data mode category 5064 to switch between types of numerical
representations (FIGS. 79-81) of the feedback data and/or types of
graphical representations (FIGS. 82-83) of the feedback data, for
example. The numerical representations of the feedback data can be
displayed as numerical values and/or percentages, for example.
Furthermore, the graphical representations of the feedback data can
be displayed as a function of time (FIG. 82) and/or distance (FIG.
83), for example. As described herein, a user can select the
instrument controller menu 5070 from the control panel 5030 to
input directives for the surgical instrument 5020 (FIG. 93), which
can be implemented via the instrument controller 5016 (FIG. 93)
and/or the microcontroller, for example.
[0400] Referring now to FIG. 78, the second layer of information
5012 can overlay at least a portion of the first layer of
information 5010 on the display 5002. Furthermore, the touch screen
5004 can allow a user to manipulate the second layer of information
5012 relative to the video feedback in the underlying first layer
of information 5010 on the display 5002. For example, a user can
operate the touch screen 5004 to select, manipulate, reformat,
resize, and/or otherwise modify the information displayed in the
second layer of information 5012. In certain embodiments, the user
can use the touch screen 5004 to manipulate the second layer of
information 5012 relative to the surgical instrument 5020 depicted
in the first layer of information 5010 on the display 5002. A user
can select a menu, category and/or classification of the control
panel 5030 thereof, for example, and the second layer of
information 5012 and/or the control panel 5030 can be adjusted to
reflect the user's selection. In various embodiments, a user may
select a category from the instrument feedback category 5036 that
corresponds to a specific feature or features of the surgical
instrument 5020 depicted in the first layer of information 5010.
Feedback corresponding to the user-selected category can move,
locate itself, and/or "snap" to a position on the display 5002
relative to the specific feature or features of the surgical
instrument 5020. For example, the selected feedback can move to a
position near and/or overlapping the specific feature or features
of the surgical instrument 5020 depicted in the first layer of
information 5010.
[0401] Referring to FIGS. 79 and 80, if a user selects the knife
progression category 5040 from the instrument feedback menu 5036,
for example, the sensed data and/or information related to the
progression of the knife can move and/or "snap" to a position in
the second layer of information 5012 relative to the knife of the
DLU 5022 depicted in the first layer of information 5010, for
example. Furthermore, the control panel 5030 can be collapsed
and/or minimized after the user selects the desired category or
categories from the instrument feedback menu 5036. Feedback data
5052 related to the progression of the knife can be depicted on the
display 5002 near the detected knife of the DLU 5022 depicted in
the first layer of information 5010, and can move between a first
position (FIG. 79) when the knife is near the beginning of the
firing stroke and a second position (FIG. 80) when the knife is
near the distal end of the firing stroke, for example, as the knife
translates and/or moves through the DLU 5022. For example, when the
knife has translated a distance X mm, the data 5052 related to the
knife's progression can be positioned in the first position (FIG.
79), and, when the knife has translated a distance Y mm, the data
5052 related to the knife's progression can be positioned in the
second position (FIG. 80). In such embodiments, the operator may
track the progression of the knife during the firing stroke by
viewing the feedback data 5052 on the screen 5002. For example,
when the knife of the DLU 5022 is blocked from view by the end
effector jaws 5024 and/or tissue T, for example, the operator can
track and/or approximate the position of the knife in the DLU 5020
based on the changing value of the feedback data 5052 and/or the
shifting position of the feedback data 5052 relative to the DLU
5022 depicted in the underlying first layer of information 5010.
Furthermore, the display 5002 can incorporate a numerical
representation of the knife's progression, as well as a pictorial
and/or symbolic representation of the knife's progression. For
example, a symbol 5054, such as an arrow, for example, can move
and/or extend relative to the DLU 5022 depicted in the underlying
first layer of information 5010 to show the progression of the
knife through the DLU 5022. Referring still to FIGS. 79 and 80, for
example, the symbol 5054 can extend distally as the knife advances
distally from a position near the beginning of the firing stroke
(FIG. 79) to a position near the distal end of the firing stroke
(FIG. 80), for example.
[0402] In various embodiments, a user can select one or more
different categories of feedback data from the instrument feedback
menu 5036, and the different categories of feedback data can be
displayed in the second layer of information 5012 on the display
5002. In such embodiments, when a user selects a different category
of feedback data from the instrument feedback menu 5036, a
numerical and/or symbolic representation of the feedback data can
move to an appropriate position on the display 5002 relative to the
DLU 5022 depicted in the underlying first layer of information
5010. For example, if a user selects the jaw position category 5038
from the instrument feedback menu 5036, feedback data related to
the position of a moveable jaw between an open position and a
clamped position can be displayed in the second layer of
information 5012, and can move to a position near the moveable
jaw(s) 5024 of the surgical instrument 5020 on the display 5002,
for example. Furthermore, if the knife speed category 5042 is
selected, feedback data 5058 (FIG. 82) related to the velocity of
the knife can be displayed in the second layer of information 5012,
and can move to a position near the knife in the DLU 5022 on the
display 5002, similar to the numerical data 5052 and/or the symbol
5054 discussed above. If the tissue thickness category 5044 is
selected by a user, feedback data related to the detected tissue
thickness can be displayed in the second layer of information 5012,
and can move to a position near the measured tissue T on the
display 5002, for example. Furthermore, in at least one embodiment,
the second layer of information 5012 can include a scale and/or a
ruler, which can illustrate the detected tissue thickness. The user
can move the ruler via the touch screen 5004 relative to the
underlying tissue T depicted in the first layer of information
5010, which may facilitate the user's appreciation of the tissue
thickness variations, for example. If a user selects the end
effector articulation category 5046, feedback data 5252 (FIGS.
84-88) related to the articulation of the DLU 5022 can be displayed
in the second layer of information 5012, and can move to a position
near the articulation joint 5026 (FIGS. 84 and 85) of the DLU 5022
on the display 5002, for example. If a user selects the firing
force category 5048, the feedback data related to the firing force
exerted on the tissue by the knife can be displayed in the second
layer of information 5012, and can be positioned near the knife of
the DLU 5022 on the display 5002, for example. Additionally, the
feedback data related to the firing force exerted by the knife can
move in the second layer of information 5012 as the knife moves
relative to the DLU 5022, for example, during a firing stroke.
Furthermore, if the clamping force category 5050 is selected,
feedback data 5158 (FIG. 83) related to the clamping force on the
tissue T can be depicted in the second layer of information 5012,
and can move near the DLU 5022 depicted in the underlying first
layer of information 5010. In such embodiments, the feedback data
5158 related to the clamping force can show variations in the
clamping pressure along the length and/or width of the DLU 5022,
during clamping, and/or throughout a firing stroke, for
example.
[0403] In various embodiments, the feedback depicted in the second
layer of information 5012 can move with the corresponding feature
of the surgical instrument 5020 in the first layer of information
5010. For example, as the DLU 5022 is manipulated around the
surgical site, the DLU 5022 may move around the display 5002. In
such embodiments, the feedback related to the DLU 5022, such as the
jaw position and/or the articulation data, for example, can move
along with the DLU 5022. Movement of the relevant feedback may
ensure the feedback remains in the operator's field of vision
without requiring the operator to move their eyes away from the
corresponding feature of the surgical instrument 5020 depicted in
the first layer of information 5010 on the display 5002.
Furthermore, the movement of the relevant feedback may ensure the
feedback does not block the feature(s) of the surgical instrument
5020 depicted in the first layer of information 5010 that the
operator desires to view on the display 5002.
[0404] In certain embodiments, a user can select multiple feedback
categories to view on the display 5002 simultaneously. Furthermore,
the selected feedback(s) can be automatically arranged on the
display 5002 to display the relevant data in a non-overlapping
arrangement in the second layer of information 5012. In other
words, feedback displayed in the second layer of information 5012
may not overlap other feedback displayed in the second layer of
information 5012; however, such feedback may overlap the video
feedback of the first layer of information 5010 displayed on the
display 5002, for example. In various embodiments, when the
feedback data moves and/or "snaps" to a position on the screen
relative to the surgical instrument 5020 depicted in the underlying
first layer of information 5010, the user can override the default
position by "dragging and dropping" the feedback data elsewhere in
the second layer of information 5012.
[0405] Referring now to FIG. 81, a symbolic representation 5056 of
the progression of the knife, such as a cross, bulls-eye, and/or
pictorial representation of the knife and/or knife edge, for
example, can move to a position in the second layer of information
5012 that overlaps the position of the knife depicted in the first
layer of information 5010. In certain embodiments, even when the
knife is not visible on the display 5002, for example, if the view
of the knife is obstructed, the symbolic representation 5056 of the
knife can move and/or follow the detected position of the knife in
the DLU 5022 on the screen 5002. For example, the symbolic
representation 5056 can be in a first position relative to the DLU
5022 near the beginning of the firing stroke, and the symbolic
representation 5056 move to a second position relative to the DLU
5022 near the end of the firing stroke.
[0406] In various embodiments, feedback selected by the user via
the touch screen 5004, can "snap" to a corner, edge and/or other
predetermined location on the display 5002. For example, referring
still to FIG. 81, numerical data 5052 related to the knife's
progression can move to a corner of the display 5002. Additionally
or alternatively, a user can interface with the touch screen 5004
to move the numerical data 5052 to a different position on the
touch screen 5004. Based on the position of the underlying surgical
instrument 5020 in the first layer of information 5010, the user
may move the numerical data 5052 to a position in the second layer
of information 5012 such that a corresponding and/or specific
feature of the DLU 5022 is not blocked and/or obstructed by the
numerical data 5052. Additionally or alternatively, the user may
move the numerical data 5052 to a position near the corresponding
feature of the DLU 5022, such that the user can easily view the
corresponding DLU 5022 feature and the numerical data 5052
simultaneously.
[0407] Referring to FIGS. 84 and 85, a symbolic representation 5254
(FIG. 85) of feedback data from the feedback controller 5016 (FIG.
93) can be included I the second layer of information 5012. For
example, a symbolic representation 5254 of the articulation of the
DLU 5022, such as a subtended angle and/or arc, for example can be
depicted in the second layer of information 5012, and can move to a
position on the display 5002 near and/or overlapping the
articulation joint 5026 of the surgical instrument 5020 depicted in
the first layer of information 5010. For example, a subtended arc
can extend between an axis A defined by the non-articulated DLU
5022 (FIG. 84) and an axis A' defined by the articulated DLU 5022
(FIG. 85). In certain embodiments, even when the articulation joint
5026 is not visible on the screen, the symbolic representation 5254
of the articulation angle can be visible in the second layer of
information 5012. For example, if the articulation joint 5026 is
not positioned within the endoscope's field of view and/or is
obstructed or blocked, the symbolic representation 5254 of the
articulation angle can provide a visible indication of articulation
to the user. In various embodiments, the symbolic representation
5252 can adjust and/or change as the DLU 5022 moves and/or
articulates. For example, the symbolic representation 5254 can be
an arrowed arc or line, which can extend from the initial and/or
non-articulated position of the DLU 5022 (FIG. 84) toward the
articulated position of the DLU 5022 (FIG. 85) as detected by the
instrument 5020. Furthermore, in various embodiments, the symbolic
representation 5254 can "snap" to a position relative to the DLU
5022 depicted in the first layer of information, such that the
symbolic representation 5254 overlaps and/or is aligned with the
DLU 5022. For example, referring primarily to FIG. 85, the symbolic
representation 5254 of the articulation angle can move at and/or
near the articulation joint 5026 depicted in the first layer of
information 5010 on the display 5002, and can lengthen between the
axis A defined by the DLU 5022 in the initial and/or
non-articulated position and the axis A' defined by the DLU 5022 as
the DLU 5022 articulates.
[0408] Furthermore, in various embodiments, numerical data 5252
related to the articulation of the DLU 5022 can be displayed in the
second layer of information 5012 on the display 5002. Furthermore,
the data 5252 can change as the DLU 5022 articulates. For example,
the second layer of information 5012 can depict an articulation of
X.degree. before the DLU 5022 articulates (FIG. 84), and can depict
an articulation of Y.degree. after the DLU 5022 articulates (FIG.
85). In various embodiments, the feedback data 5252 related to the
articulation of the DLU 5022 can be displayed in the second layer
of information 5012 at and/or near the articulation joint 5026 of
the surgical instrument 5020 depicted in the first layer of
information 5010, for example. A user can utilize the touch screen
5004 to move, resize, minimize, and/or otherwise manipulate the
articulation data 5252 displayed in the second layer of information
5012 relative to the video feedback displayed in the first layer of
information 5010, for example. Additionally or alternatively, a
user can interface with the touch screen 5004 to move the symbolic
representation 5254 and/or the numerical data 5252 to a different
position on the touch screen 5004. Based on the position of the
underlying surgical instrument 5020 in the first layer of
information 5010, the user may move the numerical data 5252 to a
position in the second layer of information 5012 such that specific
feature(s) of the DLU 5022 are not blocked and/or obstructed by the
numerical data 5252. Additionally or alternatively, the user may
move the numerical data 5252 to a position near the corresponding
feature(s) of the DLU 5022, such that the user can easily view the
corresponding DLU 5022 feature(s) and the numerical data 5252
simultaneously.
[0409] Referring now to FIG. 82, a graphical representation can be
selected from the display menu 5060 of the control panel 5030 by
way of the touch screen 5004, for example. In such embodiments, a
graphical representation of feedback 5058 can be displayed in the
second layer of information 5012 on the display 5002. A user may
select the graphical representation to view measured and/or sensed
data from the surgical instrument 5020 and/or the controller
thereof relative to time and/or space. For example, a user may
desire to observe the velocity of the firing element throughout the
firing stroke, and thus, may select the knife speed category 5042
(FIG. 78) from the instrument feedback menu 5036 (FIG. 78). In such
embodiments, the graphical representation 5058 of the speed of the
knife can continue to gain data points and grow during the firing
stroke, for example. In various embodiments, at the completion of
the firing stroke, the graphical representation 5058 can depict a
"soft" start period 5057 and/or a "soft" stop period 5059 of the
knife. Furthermore, the graphical representation 5058 can be
positioned on the display 5002 such that the velocity of the knife
at a specific location along the length of the end effector jaws
5024 corresponds to that specific location along the length of the
end effector jaws 5022 depicted in the first layer of information
5010. For example, the graphical representation 5058 can begin at
and/or near the beginning of the knife's path through the DLU 5022
depicted in the first layer of information 5010, and can end at
and/or near the end of the knife's path through the DLU 5022
depicted in the first layer of information 5010, for example.
Furthermore, as described herein, the graphical representation 5058
can "snap" to an appropriate position on the screen, and a user can
utilize the touch screen 5004 to move and/or resize the graphical
representation 5058 as desired. In certain embodiments, a numerical
representation of the firing speed can be depicted in the second
layer of information 5012 along with the graphical representation
5058.
[0410] Referring now to FIG. 83, in various embodiments, a user may
desire to observe the clamping force exerted on the tissue T along
the length and/or width of the end effector jaws 5024, and thus,
may select the clamping force category 5050 (FIG. 78) from the
instrument feedback menu 5036 (FIG. 78). In such embodiments, a
graphical representation 5158 of the clamping force can be depicted
in the second layer of information 5012. In some embodiments, the
graphical representation 5158 can be arranged in the second layer
of information 5012 relative to the clamped tissue depicted in the
first layer of information 5010. For example, the graphical
representation 5158 can begin at and/or near the proximal end of
the jaws 5024 depicted in first layer of information 5010, and can
end at and/or near the distal end of the jaws 5024 depicted in the
first layer of information 5010, for example. Furthermore, as
described herein, the graphical representation 5158 can "snap" to
an appropriate position on the screen, and a user can utilize the
touch screen 5004 to move and/or resize the graphical
representation 5158, for example. In certain embodiments, the
graphical representation can change during use to reflect
variations in clamping pressure during a firing stroke, for
example.
[0411] Referring to FIGS. 86-88, in various embodiments, a user can
interface with the touch screen 5004 to input controls and/or
directives to the surgical instrument 5020 via the instrument
controller 5016 and/or microcontroller. For example, a user can
input controls directed to articulating the DLU 5022, clamping the
end effector jaws 5024, advancing and/or retracting the cutting
element, and/or ejecting staples from the DLU 5022. In various
embodiments, a user can select the instrument controller category
5070 from the control panel 5030 via the touch screen 5004 to
activate the instrument-control state, such that the user can
control the surgical instrument 5020 via the touch screen 5004.
When the touch screen 5004 is activated for instrument control, a
user can interface with the touch screen 5004 to control the
surgical instrument 5020. For example, a user can interface with
control buttons and/or icons in the second layer of information
5012 and/or can interface with locations on the touch screen 5004
corresponding to the underlying surgical instrument 5020 to input
directives to the surgical instrument 5020, for example.
[0412] For example, referring to FIG. 86, a user can interface with
the touch screen 5004 to indicate the desired articulation
direction and degree of the DLU 5022, for example. In certain
embodiments, a user can drag a contact point across the touch
screen 5004 from at and/or near the DLU 5022 toward the desired
articulated location of the end effector 5002. Referring to FIG.
86, a user can trace a line or arc 5352 from at and/or near the DLU
5022 depicted in the first layer of information 5010 toward the
desired articulation location of the DLU 5022. For example, the arc
5352 can extend from and/or approximately from the axis A defined
by the DLU 5022, and the arc 5352 can extend to the axis A' defined
by the desired articulated position of the DLU 5022. Furthermore,
the arc 5352 can extend in the direction indicated by the arrow
5354, for example. In certain embodiments, an arc 5352 may not
appear in the second layer of information 5010 when the user inputs
the desired articulation via the touch screen 5004. In various
embodiments, the touch screen 5004 can communicate the desired
articulation angle to the instrument controller 5016 (FIG. 93)
and/or microcontroller, which can effect the articulation of the
DLU 5022 to the desired articulation angle. Referring now to FIG.
88, the instrument controller 5016 (FIG. 93) and/or microcontroller
can effect articulation of the DLU 5022 to the axis A' based on the
input of the user via the touch screen 5004, for example.
[0413] Referring primarily to FIG. 87, in various embodiments, a
user can interface with control buttons, schematics, and/or icons
in the first layer of information 5012 to input directives to the
surgical instrument 5020. For example, the first layer of
information 5012 can include a symbol or icon 5356, and the user
can move and/or manipulate the icon 5356 to effect articulation of
the DLU 5022. In various embodiments, the icon 5356 can include a
schematic of the DLU 5022, for example. Furthermore, the user can
drag the icon 5356 to an articulated and/or rotated orientation to
effect articulation of the DLU 5022. In various embodiments, a line
and/or arc 5358 can indicate the direction and/or degree of
articulation desired by the user. For example, the arc 5358 can
extend from the non-articulated orientation of the icon 5356 to the
articulated orientation of the icon 5356'. The articulated icon
5356' can correspond to the desired articulation of the DLU 5022,
for example. Referring now to FIG. 88, the instrument controller
5016 and/or microcontroller can effect articulation of the DLU 5022
to the axis A' based on the input of the user via the touch screen
5004, for example. For example, the DLU 5022 can be articulated to
the subtended angle defined by the arc 5358 between the
non-articulated icon 5356 and the articulated icon 5356' shown in
FIG. 87.
[0414] Referring primarily to FIGS. 89 and 90, in various
embodiments, a user can interface with the touch screen 5004 to
input directives to the surgical instrument 5020 related to the
closure of the jaws 5024. In certain embodiments, a user can drag a
contact point across the touch screen 5004 from at and/or near the
moveable jaw 5024 toward the closed orientation of the moveable jaw
5024 to initiate closure of the jaw 5024. For example, a user can
trace a line or arc 5362 (FIG. 89) from at and/or near the moveable
jaw 5024 depicted in the first layer of information 5010 toward the
desired closed orientation of the moveable jaw 5024. In various
embodiments, the touch screen 5004 can communicate the closure
motion to the instrument controller 5016 and/or microcontroller,
which can affect the closure of the moveable jaw(s) 5024. In
certain embodiments, the arc 5362 traced by the user on the touch
screen 5004 can extend from and/or approximately from the axis A
defined by the moveable jaw 5024, and the arc 5362 can extend to
the axis A' (FIG. 90) defined by the desired clamped orientation of
the moveable jaw 5024. Furthermore, the arc 5362 can extend in the
direction indicated by the arrow 5364, for example. Referring now
to FIG. 90, the instrument controller 5016 and/or microcontroller
can affect closure of the moveable jaw 5024 to the axis A' based on
the input of the user via the touch screen 5004, for example.
[0415] Referring now to FIGS. 91 and 92, in various embodiments, a
user can interface with control buttons and/or icons in the first
layer of information 5012 to input directives to the surgical
instrument 5020. For example, the first layer of information 5012
can include a control interface 5072, which can include buttons
5074, 5075, 5076, 5077, 5078 for inputting directives to the
instrument controller 5016 and/or microcontroller, for example.
Buttons for inputting directives to the instrument controller 5016
(FIG. 93) and/or microcontroller can relate to articulating the DLU
5022, closing and/or clamping the jaws 5024, firing and/or
retracting the cutting element, and/or ejecting staples from the
DLU 5022, for example. The user can interface with the touch screen
5004 to select a button or buttons from the control interface 5072.
Referring primarily to FIG. 91, the control interface 5072 can
include a stop/retract button 5474, a pause button 5475, a start
button 5476, a speed-up button 5477, and/or a speed-down button
5478, for example. The user can contact the start button 5476 to
initiate the firing stroke and/or advance the firing element, the
pause button 5475 to pause the firing stroke, and/or the
stop/retract button 5474 to stop the firing stroke and retract the
firing element, for example. Furthermore, the user can interface
with the control interface 5072 to adjust the speed of the firing
element throughout the firing stroke. For example, the user can
contact the speed-up button 5477 to increase the velocity of the
firing element, and the user can contact the speed-down button 5478
to decrease the velocity of the firing element. A user may increase
the velocity of the firing element after and/or during a "soft"
start phase of the firing stroke, for example, and/or may decrease
the velocity of the firing element for a "soft" stop phase of the
firing stroke toward an end of the firing stroke, for example. In
other embodiments, the control interface 5072 can include buttons
and/or controls for modifying the closure of the jaws 5024, and/or
the articulation of the DLU 5022, for example. In various
embodiments, the control interface 5072 can "snap" to a position in
the second layer of information 5012 when the instrument controller
5070 menu is selected from the control panel 5030 and/or when the
instrument-control state is otherwise selected by the user. The
user can move, adjust and/or manipulate the control interface 5072
relative to the first layer of information 5010 and/or the display
5002, for example.
[0416] In various embodiments, referring to FIG. 92, the secondary
layer of information 5012 can include a progression bar 5480, which
can indicate the position of the firing element in the DLU 5022,
for example. The progression bar 5480 can extend between a proximal
end 5482 and a distal end 5488, and can define a proximal-most
position and a distal-most position of the firing element during a
firing stroke. In various embodiments, the position of the firing
element can be indicated along the progression bar 5480, for
example. In certain embodiments, the user can use the controls in
the control interface 5072 to adjust the firing stroke. For
example, the user can interface with the control interface 5072 to
initiate and/or terminate the "soft" start and/or "soft" stop
phases of the firing stroke based on the indicated position of the
firing element along the progression bar 5480. Furthermore, the
progression bar 5480 can include measurement indicia and/or guides
5484, 5486, which can be set to positions along the progression bar
5480 where "soft" start and/or "soft" stop phases may begin and/or
end, for example. The guides 5484, 5486 can provide a visual
suggestion to the user to initiate and/or terminate the "soft"
start period with the speed-up button 5077 and/or the "soft" stop
phase with the speed-down button 5078 during the firing stroke, for
example. In various embodiments, the position of the guides 5484,
5486 can be preset by the user.
[0417] Referring still to FIG. 92, in various embodiments, the
instrument controller 5016 and/or microcontroller can automatically
affect variations in the speed of the firing element based on the
position of the guides 5484, 5486 along the progression bar 5480.
Furthermore, the user can interface with the touch screen 5004 to
move and/or manipulate the progression bar 5480, and thus, to
modify the "soft" start and "soft" stop phases of the firing
stroke. For example, the "soft" start and/or "soft" stop phases can
be set at predetermined positions along the progression bar 5480
between the proximal end 5482 and the distal end 5488. In certain
embodiments, the user can interface with the touch screen 5004 to
move and/or adjust the position of the guides 5484, 5486 along the
length of the progression bar 5480. For example, the user can
toggle the guides 5484, 5486 between a plurality of positions on
the progression bar 5480 by dragging and releasing the guides 5484,
5486 to lengthen and/or shorten the "soft" start and/or "soft" stop
phases of the firing stroke. In certain embodiments, the user can
interface with the touch screen 5004 to move and/or adjust the
position of the distal end 5488 of the progression bar 5480 to
lengthen and/or shorten a firing stroke. For example, the user can
drag the distal end 5488 proximally to shorten the firing stroke.
and/or can drag the distal end 5488 distally to lengthen the firing
stroke, for example. In various embodiments, the instrument
controller 5016 and/or microcontroller can adjust the speed of the
firing element and/or firing stroke length based on the modified
positions of the guides 5484, 5486 and/or the distal end 5488 along
the progression bar 5480, for example.
[0418] In various embodiments, the surgical instrument 10 can
include at least one deactivation mechanism. As described in
greater detail herein, such a deactivation mechanism can discourage
an end user from tampering with the surgical instrument. For
example, referring now to FIG. 134, a power source 2500 is
illustrated. The power source 2500 can be used to supply power to a
surgical instrument such as, for example, the surgical instrument
10 (See FIG. 1) and is similar in many respects to other power
sources described elsewhere in this document such as, for example,
the power source 200 (See FIG. 1), and other power sources of the
type described in further detail Zemlok '763, which has been herein
incorporated by reference in its entirety. To protect the power
source 2500 from tampering, the power source 2500 can be configured
to become inoperable or inactive in the event it is tampered with.
For example, the power source 2500 can become inactive by ceasing
to receive, store, and/or transmit energy, for example. Protection
from tampering may ensure proper operation of the power source 2500
during use with the surgical instrument 10.
[0419] Referring to FIGS. 134 and 135, the power source 2500 may
include an outer casing 2502 which may enclose various components
of the power source 2500 such as, for example, a battery pack 2510.
The casing 2502 may include a first shell 2504 and a second shell
2506 which can be separably coupled to the first shell 2504, as
illustrated in FIG. 135. In certain examples, the shells 2504 and
2506 can be formed from a thermoplastic material such as, for
example, polycarbonate. Alternately, other materials having
appropriate characteristics may be used. Furthermore, the shells
2504 and 2506 can be coupled to each other by one or more fastening
techniques such as, for example, adhesives, welding, interlocking
structures, and/or screws. In one example, the shells 2504 and 2506
can be secured together via a snap fit type engagement. In another
example, the shells 2504 and 2506 can be secured together by
fastening members 2508, as illustrated in FIG. 135.
[0420] Referring to FIGS. 135-137, the power source 2500 may
include a deactivation mechanism 2512 which may render the power
source 2500 inoperable if the power source 2500 is compromised. For
example, the deactivation mechanism 2512 may render the power
source 2500 inoperable if the casing 2502 is tampered with. As
illustrated in FIGS. 135-137, the deactivation mechanism 2512 may
comprise a circuit 2514 which may include a breakable portion 2516
(See FIG. 136). In certain examples, the breakable portion 2516 may
be comprised of a conductive material that can be easily ruptured.
As illustrated in FIG. 136, the circuit 2514 may be coupled to the
battery pack 2510 and may allow current to flow for as long as the
breakable portion 2516 remains intact. Breaking the breakable
portion 2516, as illustrated in FIG. 137, may interrupt the circuit
2514 thereby terminating the flow of current through it. Further to
the above, as illustrated in FIG. 135, the circuit 2514 can be
positioned such that the breakable portion 2516 may be ruptured
when the first shell 2504 and the second shell 2506 are separated
from each other which may render the power source 2500 unable to
receive, store, and/or supply power to the surgical instrument 10
without a significant effort to repair the ruptured circuit
2514.
[0421] Referring to FIG. 135, the power source 2500 may comprise
one or more battery cells depending on the current load needs of
the instrument 10. In various aspects, the power source 2500 may
include a battery pack such as, for example, the battery pack 2510
which may include a plurality of battery cells which may be
connected in series with each other. The power source 2500 can be
replaceable. In certain aspects, the power source 2500 may comprise
a rechargeable battery (e.g., lead-based, nickel-based, lithium-ion
based, etc.). The battery cells may be, for example, 3-volt lithium
battery cells, such as CR 123A battery cells, although in other
embodiments, different types of battery cells could be used
(including battery cells with different voltage levels and/or
different chemistries). A user may disconnect and remove a depleted
power source 2500 from the surgical instrument 10 and connect a
charged power source 2500 in its place. The depleted power source
2500 can then be charged and reused. It is also envisioned that the
power source 2500 may include at least one disposable battery. In
various aspects, the disposable battery may be between about 9
volts and about 30 volts. A user may disconnect and remove a
depleted disposable power source 2500 and connect a new disposable
power source 2500 to power the surgical instrument 10.
[0422] As described above, the power source 2500 may include
rechargeable battery cells and can be removably placed within the
handle portion 14 of the housing 12, for example (see FIG. 1). In
such circumstances, the power source 2500 can be charged using a
charger base which may comprise a power source for charging the
power source 2500. A deactivation mechanism such as, for example,
the deactivation mechanism 2512 can be utilized to prevent the
power source 2500 from being recharged by the charger base if the
power source 2500 is tampered with as described above. For example,
the circuit 2514 may be coupled to the battery pack 2510 and may be
couplable to the charger base to permit the charger base to
recharge the battery pack 2510. As described above, the breakable
portion 2516 (See FIG. 135) may be broken when the first shell 2504
is separated from the second shell 2506 thereby interrupting
current flow through the circuit 2514 which may prevent the charger
base from recharging the battery pack 2510. This may be
advantageous in discouraging an end user from tampering with the
power source 2500 because tampering with the power source 2500 may
render it incapable of being recharged for subsequent use with the
surgical instrument 10.
[0423] Referring now to FIGS. 138-141, the power source 2500 may
include a data storage unit such as, for example, memory 2552 which
may store data including information about the power source 2500
such as, for example, total charge available, number of uses,
and/or performance. Additionally, the memory 2552 may store data
about the surgical instrument 10 including a variety of information
about the operation of the surgical instrument 10 during a surgical
procedure such as, for example, various sensor readings, number of
firings, number of cartridges utilized, and/or information about
treated patients. The memory 2552 may include any means for storing
software, including but not limited to ROM (read only memory), RAM
(random access memory), PROM (programmable ROM), EEPROM
(electrically erasable PROM), and/or other computer-readable
media.
[0424] Further to the above, referring again to FIGS. 138-141, the
power source 2500 may include a data access portal such as, for
example, I/O interface 2550 to provide access to data stored in the
memory 2552. For example, the I/O interface 2550 may allow data
stored in the memory 2552 of the power source 2500 to be downloaded
to an external computer device for evaluation and analysis. In
certain circumstances, the I/O interface 2550 may be a wired
interface and may be operably coupled to a deactivation mechanism
2512 which may include a rupturable connection that can be severed
to prevent data transmission through the I/O interface 2550.
Similar to the breakable portion 2516 of the deactivation mechanism
2512, the rupturable connection of the deactivation mechanism 2554
can be positioned such that it may be severed when the casing 2502
is breached such as, for example, when the first shell 2504 and the
second shell 2506 are separated from each other.
[0425] Further to the above, as illustrated in FIGS. 139-141, the
I/O interface 2550 may include a connector 2555 which may be
configured to receive a corresponding connector 2556 from the
external computer device, for example, to permit data transfer
between the memory 2552 and the computer device. In addition, the
connector 2554 can be protected by a cover such as, for example,
pivoting cover 2559 which may be configured to move between a
locked position (See FIG. 139), wherein the connector 2554 is
unexposed and an unlocked position (See FIG. 140), wherein the
connector 2554 is exposed to receive the corresponding connector
2556. In one example, a helical screw 2558 may be used to secure
the pivoting cover 2559 to the casing 2502. Other means for
reversibly covering the connector 2556 is contemplated by the
present disclosure. Further to the above, in certain examples, the
connectors 2554 and 2556 may include a key and lock type engagement
wherein the connectors 2554 and 2556 may comprise, for example,
unique complimenting geometries that prevent the connector 2554
from receiving other connectors in order to prevent or at least
limit unauthorized access to data stored within the memory 2552. In
certain examples, the connector 2554 can be positioned within the
casing 2502, as illustrated in FIG. 141, to further limit
unauthorized access to the data stored in the memory 2552. In such
circumstances, the connector 2554 can be accessed by separating the
first shell 2504 from the second shell 2506 of the casing 2502.
However, as described above in greater detail, the deactivation
mechanism 2512 may render the power source 2500 inoperable upon
breach of the casing 2502 which may further discourage from
attempting to expose the connector 2554 to gain access to the data
stored in the memory 2552.
[0426] Referring to FIG. 142, the power source 2500 may include a
processor 2560 which may manage the data stored in the memory 2552.
To protect such data from unauthorized access, the processor 2560
may be coupled to a breach sensing mechanism 2562. For example, the
processor 2560 may coupled to the circuit 2514 and may be
configured to detect rupture of the breakable portion 2516. In one
example, the breach sensing mechanism 2562 may include one or more
sensors configured to detect a breach in the casing 2502. In any
event, upon detecting a breach, the processor 2560 can be
programmed to prevent unauthorized access to the data stored in the
memory 2552, for example, by deleting or encrypting the data.
[0427] Referring to FIGS. 143-145, a surgical instrument 2600 is
depicted. The surgical instrument 2600 is similar to the surgical
instrument 10 (See FIG. 1) and/or the surgical instrument 2100 (See
FIG. 146) in many respects. For example, the surgical instrument
2600 may include a housing assembly 2602 which is similar to the
housing assembly 2102 of the surgical instrument 2100 and/or the
housing 12 of the surgical instrument 10. Furthermore, the surgical
instrument 2600 may include a power source 2500' which can be used
to supply power to the surgical instrument 2600 and is similar in
many respects to other power sources described elsewhere in this
document such as, for example, the power source 2500 (See FIG.
134), and other power sources of the type described in further
detail in Zemlok '763, which has been herein incorporated by
reference in its entirety. In addition, as illustrated in FIG. 143,
the power source 2500' may include a charge level indicator 2660
which can be configured to provide feedback to a user about the
charge level of the power source 2500'. The feedback can be in the
form of sound and/or light, for example. The power source 2500' may
include one or more light emitting diodes (LED). The processor
2560, for example, can be programmed to control the LEDs to provide
feedback to a user about the charge level of the power source 2500'
as can be measured by a charge meter, for example.
[0428] As illustrated in FIGS. 143-145, the power source 2500' may
include a first LED 2662 and a second LED 2664. The processor 2560
can be coupled to the LEDs 2662 and 2664 and may be programmed to
illuminate both of the LEDs 2662 and 2664 upon receiving a signal
from the charge meter that the power source is fully charged. In
addition, the processor 2560 may be programmed turn off both of the
LEDS 2662 and 2664 upon receiving a signal from the charge meter
that the power source is empty. Furthermore, the processor 2560 may
be programmed to illuminate only the first LED 2662 but not the
second LED 2664 upon receiving a signal from the charge meter that
the power source includes sufficient charge for only one complete
operation of the surgical instrument 2600. Other means for alerting
a user as to the charge level of the power source 2500' are
contemplated by the present disclosure.
[0429] In certain embodiments, various components of the surgical
instrument 10 can be reusable and various components can be
replaceable, for example. Furthermore, the surgical instrument 10
can be at least partially assembled, disassembled, and/or
reassembled. For example, the surgical instrument 10 can be at
least partially disassembled and reassembled with reusable
components and replacement components, for example. Additionally,
the surgical instrument 10 can be at least partially disassembled
for cleaning, disinfecting, and/or reprocessing between surgical
procedures. Subsequently, the surgical instrument 10 can be
reassembled, for example. As described in greater detail herein,
various features, assemblies and/or systems of the surgical
instrument 10 can facilitate disassembly and assembly thereof. For
example, referring now to FIGS. 146-148, a surgical instrument 2100
is depicted. The surgical instrument 2100 is similar to the
surgical instrument 10 (See FIG. 1) in many respects. For example,
the surgical instrument 2100 may include a housing assembly 2102
which is similar to the housing 12 of the surgical instrument 10.
In addition, the housing assembly 2102 may include several
detachable components 2103 which can be detachably secured to a
housing body 2104 such as, for example, a working assembly 2106.
Other components of the housing assembly 2102 can be detachably
secured to the housing body 2104. For example, the housing assembly
2102 may include a replaceable power source 2108 which can be
detachably secured to a handle portion 2110 of the housing body
2104. The power source 2108 is similar in many respects to other
power sources described elsewhere in this document such as, for
example, the power source 200 (See FIG. 1).
[0430] Referring again to FIG. 147, the housing assembly 2102, or
some or all of its components can be reusable. In other words, the
housing assembly 2102, or some or all of its components can be
utilized in multiple surgical procedures which may require for the
housing assembly 2102 to be cleaned, disinfected, and/or
reprocessed between surgical procedures. The ability to reversibly
disassemble the housing assembly 2102, or remove some or all of its
components such as, for example, the working assembly 2106 in a
simple and reproducible manner may simplify the steps of cleaning,
disinfecting, and/or reprocessing of the housing assembly 2012
and/or may reduce cost.
[0431] Referring to FIG. 147, the housing assembly 2102 may be
disassembled following a surgical procedure and the components of
the disassembled housing assembly 2102 such as, for example, the
housing body 2104, the working assembly 2106 and/or the power
source 2110 can be cleaned, disinfected, and/or reprocessed each
separately or in combination with other components depending on the
characteristics and internal parts of each component. In certain
examples, the housing body 2104 can be disposable. Said another
way, the housing assembly 2102 may be disassembled following a
surgical procedure and the housing body 2104 can be replaced with a
new housing body 2104. The remaining components, however, can be
cleaned, disinfected, and/or reprocessed then attached to the new
housing body 2104. The reader will appreciate that other components
of the housing assembly 2102 can also be disposable and can be
replaced with new like components.
[0432] Referring again to FIGS. 146-148, the housing body 2104 can
be configured to permit assembly and disassembly of the housing
assembly 2102 in a simple, predictable, and reproducible manner.
For example, the housing body 2104 can include a first shroud
portion 2112 (See FIG. 147) and a second shroud portion 2114 (See
FIG. 146) which can be releasably attached to the first shroud
portion 2112. In one example, the shroud portions 2112 and 2114 can
include a snap fit type engagement. The shroud portions 2112 and
2114 can be adapted for matting engagement with each other. In one
example, the shroud portion 2112 can include a plurality of female
members 2116 (See FIG. 147) which may be cylindrical in shape and
configured to receive corresponding male members (not shown)
disposed on the shroud portion 2114 in a snap fit engagement when
the shroud portions 2112 and 2114 are assembled together.
[0433] Further to the above, the working assembly 2106 can be
nested in the first shroud portion 2112. As illustrated in FIG.
147, the second shroud portion 2114 can be removed to expose the
working assembly 2106 nested in the first shroud portion 2112 in
order to permit a user to remove the working assembly 2106 from the
housing body 2104. The working assembly 2106, as illustrated in
FIG. 147, may include a motor 2118 which may generate rotational
motions to effectuate an end effector (e.g., the cartridge/anvil
portion of the loading unit 20 illustrated in FIG. 2). The motor
2118 is similar in many respects to other motors described
elsewhere in this document such as, for example, the motor 100 (See
FIG. 1). In addition, the working assembly 2106 may also include a
transmission assembly 2120 which can be operably coupled to the
motor 2118 and is similar in many respects to other transmission
assemblies described elsewhere in this document such as, for
example, the gear assembly 170 (See FIG. 5). Furthermore, the
working assembly 2106 may also include a firing member assembly
2122 which may transform the rotational motions generated by the
motor 2118 into axial motions which can be transmitted to the end
effector through a firing rod 2124. The firing member assembly 2122
is similar in many respects to other drive assemblies described
elsewhere in this document such as, for example, the firing member
assembly 82.
[0434] Referring to FIGS. 147 and 148, the first shroud portion
2112 may include a plurality of compartments designed and spaced to
receive the working assembly 2106. For example, the shroud portion
2112, as illustrated in FIG. 147, may include a motor nesting
compartment 2126 which can be spaced to accommodate the motor 2118.
In certain examples, the motor nesting compartment 2126 can be
designed to fit the motor 2118 in a specific arrangement to ensure
accurate assembly. In addition, the motor nesting compartment 2126
may include assembly instructions which can be, for example, molded
onto a wall of the motor nesting compartment 2126 to ensure correct
assembly. For instance, the side walls of the motor nesting
compartment 2126 can be configured to closely receive the motor
2118. Moreover, the sideways can be asymmetrically configured, at
least in some respects, to receive the motor 2118 in only one
orientation, i.e. the correct orientation.
[0435] Similarly, the shroud portion 2112, as illustrated in FIG.
147, may include a transmission assembly nesting compartment 2128
which can be spaced to accommodate the transmission assembly 2120.
Furthermore, in certain examples, the transmission assembly nesting
compartment 2128 can be designed to fit the transmission assembly
2120 in a specific arrangement to ensure accurate assembly. For
instance, the side walls of the transmission assembly nesting
compartment 2128 can be configured to closely receive the
transmission assembly 2120. Moreover, the sideways can be
asymmetrically configured, at least in some respects, to receive
the transmission assembly 2120 in only one orientation, i.e. the
correct orientation. In addition, the transmission assembly nesting
compartment 2128 may include assembly instructions which can be,
for example, molded onto a wall of the transmission assembly
nesting compartment 2128 to ensure correct assembly. Similarly, the
shroud portion 2112, as illustrated in FIG. 147, may include a
firing member assembly nesting compartment 2130 which can be spaced
to accommodate the firing member assembly 2122. Furthermore, in
certain examples, the firing member assembly nesting compartment
2130 can be designed to fit the firing member assembly 2122 in a
specific arrangement to ensure accurate assembly. For instance, the
side walls of the firing member assembly nesting compartment 2130
can be configured to closely receive the firing member assembly
2122. Moreover, the sideways can be asymmetrically configured, at
least in some respects, to receive the firing member assembly 2122
in only one orientation, i.e. the correct orientation. In addition,
the firing member assembly nesting compartment 2130 may include
assembly instructions which can be, for example, molded onto a wall
of the firing member assembly nesting compartment 2130 to ensure
correct assembly. The reader will appreciate that other components
of the working assembly 2106 may also be provided with unique
designated accommodating compartments within the shroud portion
2112. The reader will also appreciate that electrical contacts for
the components of the working assembly 2106 can also be embedded
with the compartments of the shroud portion 2112 such that upon
correct assembly, electrical connections can be established between
the working assembly 2106, other components of the housing assembly
2102 such as, for example, the power source 2108, and/or other
components of the surgical instrument 2100.
[0436] Further to the above, the working assembly 2106 can be
separably coupled to the firing rod 2124, as illustrated in FIG.
147, which may permit a user to remove and reconnect the working
assembly 2106 as a single unit to the surgical instrument 2100 to
simplify disassembly and reassembly of the working assembly 2106.
In one example, as illustrated in FIG. 147, the firing member
assembly 2122 may include a hollow tubular distal portion 2132
which may include a distal opening configured to receive and
releasably lock onto a proximal portion 2134 of the firing rod 2124
in a snap fit type engagement, for example.
[0437] Referring again to FIGS. 147 and 148, other components of
the housing assembly 2102 can be nested in dedicated compartments
in the shroud portion 2112 in a similar manner to the working
assembly 2106. For example, the shroud portion 2112 may include a
power source nesting compartment 2136 which can be spaced to
accommodate the power source 2108. Furthermore, in certain
examples, the power source nesting compartment 2136 can be designed
to fit the power source 2108 in a specific arrangement to ensure
accurate assembly. For instance, the side walls of power source
nesting compartment 2136 can be configured to closely receive the
power source 2108. Moreover, the sideways can be asymmetrically
configured, at least in some respects, to receive power source 2108
in only one orientation, i.e. the correct orientation. In addition,
the power source nesting compartment 2136 may include assembly
instructions which can be, for example, molded onto a wall of the
power source nesting compartment 2136 to ensure correct
assembly.
[0438] Further to the above, as illustrated in FIGS. 147 and 148,
certain user input mechanisms such as, for example, firing button
2138 and/or closure switch 2140 can also be detachable from the
housing body 2104 which may include a firing button nesting
compartment 2142 spaced to accommodate the firing button 2138
and/or a closure switch nesting compartment 2144 spaced to
accommodate the closure switch 2140. Furthermore, in certain
examples, the firing button nesting compartment 2142 can be
designed to fit the firing button 2138 in a specific arrangement to
ensure accurate assembly. For instance, the side walls of firing
button nesting compartment 2142 can be configured to closely
receive the firing button 2138. Moreover, the sideways can be
asymmetrically configured, at least in some respects, to receive
the firing button 2138 in only one orientation, i.e. the correct
orientation. Similarly, the closure switch nesting compartment 2144
can be designed to fit the closure switch 2140 in a specific
arrangement to ensure accurate assembly. For instance, the side
walls of closure switch nesting compartment 2144 can be configured
to closely receive the closure switch 2140. Moreover, the sideways
can be asymmetrically configured, at least in some respects, to
receive the closure switch 2140 in only one orientation, i.e. the
correct orientation. In addition, the firing button nesting
compartment 2142 and/or the closure switch nesting compartment 2144
may include assembly instructions which can be, for example, molded
onto a wall of the firing button nesting compartment 2142 and/or
the closure switch nesting compartment 2144 to ensure correct
assembly.
[0439] Referring again to FIGS. 147 and 148, in addition to the
nesting compartments, the shroud portion 2112 can include securing
mechanism(s) to secure some or all of the detachable components
2103 of the housing assembly 2102 in their respective compartments
to ensure that the detachable components 2103 remain nested in
their respective compartments. Such securing mechanisms may include
securing members which can be movable between an unlocked
configuration (See FIG. 148) and a locked configuration (See FIG.
147) to lock the detachable components 2103 of the housing assembly
2102 to their respective compartments in the shroud portion 2112.
The reader will appreciate that a single or multiple securing
members can be utilized to secure one or more of the detachable
components 2103 to the shroud portion 2112. In addition, the
securing mechanisms may also include safety features that may
prevent the securing members from moving to the locked
configuration in event of incorrect assembly to ensure correct
assembly of the detachable components 2103 of the housing assembly
2102. As illustrated in the exemplary embodiment in FIG. 147, the
working assembly 2106 can be secured to the shroud portion 2112 by
several of the securing members such as, for example, a motor
securing member 2148, a transmission assembly securing member 2150,
and/or a firing member assembly securing member 2152. In certain
examples, as illustrated in FIG. 147, a power source securing
member 2154, a firing button securing member 2156, and a closure
switch securing member 2158 can be utilized to secure the power
source 2108, the firing button 2138, and the closure switch 2140,
respectively.
[0440] The securing members may clamp onto the detachable
components 2103 by moving from the unlocked configuration (See FIG.
148) to the locked configuration (See FIG. 147). For example, the
motor securing member 2148 may clamp onto the motor 2118 by moving
from the unlocked configuration (See FIG. 148) to the locked
configuration (See FIG. 147). In certain examples, some or all of
the detachable components 2103 may comprise tracks configured to
receive the securing members as they move from the unlocked
configuration to the locked configuration. The tracks can be
positioned such that they may be aligned to receive the moving
securing members only when the detachable components 2103 are
correctly nested within their respective compartments in the shroud
portion 2112. For example, if the motor 2118 is not correctly
nested in the motor nesting compartment 2126, the motor securing
member 2148 may not be correctly aligned with its track and as such
upon moving the motor securing member 2148 from the unlocked
configuration to the locked configuration, the motor securing
member 2148 may not enter the track and, for example, may abut
against an outer wall of the motor 2118. In certain examples, the
motor securing member 2148 can be positioned such that it may
prevent the first shroud portion 2112 from mating engagement with
the second shroud portion 2114 if a user attempts to assemble the
shroud portions 2112 and 2114 while the motor securing member 2148
is not in the locked configuration. This arrangement may alert a
user to recheck the assembled components of the housing assembly
2102 for correct assembly.
[0441] Similar to the motor securing member 2148, the transmission
assembly securing member 2150 may be received in a dedicated track
on the transmission assembly 2120 and the transmission assembly
securing member 2150 can be positioned such that it aligns with its
respective track only if the transmission assembly 2120 is
correctly nested in the transmission assembly nesting compartment
2128. In addition, the firing member assembly securing member 2152
may be received in a dedicated track on the firing member assembly
2122, for example, and the firing member assembly securing member
2152 can be positioned such that it aligns with its track only if
the firing member assembly 2122 is correctly nested in the firing
member assembly nesting compartment 2130. Also similar to the motor
securing member 2148, the transmission assembly securing member
2150 and/or the firing member assembly securing member 2152 can be
positioned such that either may prevent the first shroud portion
2112 from mating engagement with the second shroud portion 2114 if
a user attempts to assemble the shroud portions 2112 and 2114 while
the transmission assembly securing member 2150 and/or the firing
member assembly securing member 2152 are not in the locked
configuration. As described above, some of the detachable
components 2103 can be detached and reattached to the shroud member
2112 together as an assembly and can be secured by a plurality of
the securing members. For example, the working assembly 2106 can be
secured to the shroud portion 2112 by the motor securing member
2148, the transmission assembly securing member 2150 and/or the
firing member assembly securing member 2152, as illustrated in FIG.
147. Such arrangement may provide an additional level of insurance
of correct assembly as failure to correctly assemble any one of the
components of the working assembly 2106 may prevent its
corresponding securing member from reaching the locked
configuration which may prevent the first shroud portion 2112 from
mating engagement with the second shroud portion 2114 if a user
attempts to assemble the shroud portions 2112 and 2114 while at
least one of the securing members remains short of the locked
configuration.
[0442] Referring again to FIGS. 147 and 148, some or all of the
securing members can be pivotally attached to the first shroud
portion 2112 and can be movable relative to the first shroud
portion 2112 from the unlocked configuration (See FIG. 148) to the
locked configuration (See FIG. 147), and vice versa. In certain
examples, the second shroud portion 2114 can include protruding
securing members (not shown) configured to be received within
corresponding receiving member (not shown) in the detachable
components 2103 nested in the first shroud portion 2112 when the
shroud portions 2112 and 2114 are aligned for mating engagement
during assembly of the housing assembly 2102. The protruding
securing members may ensure that the detachable components 2103
remain secured in the first shroud portion 2112. In addition, the
protruding securing members may prevent the first shroud portion
2112 from mating engagement with the second shroud portion 2114 if
a user attempts to assemble the shroud portions 2112 and 2114 while
the protruding securing members are not be properly aligned with
their corresponding receiving members, for example due to incorrect
assembly of the detachable components 2103, which may alert the
user to recheck the assembly of the detachable components 2103 of
the housing assembly 2102 for correct assembly. The reader will
appreciate that the positions of the protruding securing members
and their respective receiving members can be reversed such that
the protruding securing members can be configured to protrude from
the detachable components 2103 and be received in corresponding
receiving member on the second shroud portion 2114. In any event,
the protruding securing members and their corresponding receiving
members can be releasably attachable to one another in a snap fit
type engagement, for example. Other engagement mechanisms are
contemplated by the present disclosure.
[0443] Further to the above, some or all of the detachable
components 2103 may include camming surfaces configured to receive
the securing members of the first shroud portion 2112 as they are
moved from the unlocked configuration (See FIG. 148) to the locked
configuration (See FIG. 147). The camming surfaces can be disposed
on an outer surface of some or all of the detachable components
2103 and may allow corresponding securing members to apply pressure
onto the detachable components 2103 in the locked configuration.
For example, the motor 2118 may include a camming surface along its
track. As the motor securing member 2148 is moved from the unlocked
configuration (See FIG. 148) to the locked configuration (See FIG.
147), the motor securing member 2148 may travel along the camming
surface on the motor 2118 which may allow the motor securing member
2148 to apply an increasing pressure onto the motor 2118 with a
maximum pressure, for example, at the locked configuration. The
pressure applied onto the motor 2118 may assist in securing the
motor in the motor nesting compartment 2126.
[0444] As discussed above, an end effector can include a firing
member which can be advanced distally to staple and/or incise
tissue. Referring now to FIG. 155, an end effector 11260 can
comprise a first jaw including an anvil 11262 and a second jaw
including a staple cartridge 11264. The end effector 11260 can
further comprise, one, a housing and/or frame 11261 extending
proximally from the anvil 11262 and the staple cartridge 11264 and,
two, a firing member 11266 which can be moved relative to the
housing 11261, the anvil 11262, and the cartridge 11264. The end
effector 11260 can further comprise an articulation joint 11230
configured to permit the anvil 11262 and the cartridge 11264 to be
articulated by an articulation driver 11268. In use, the end
effector 11260 can be assembled to a shaft 11240 of a surgical
instrument, for example, such that, one, the end effector housing
11261 is coupled to a shaft housing 11241 configured to support the
end effector housing 11261, two, the end effector firing member
11266 is coupled to a shaft firing actuator 11246 configured to
advance and retract the end effector firing member 11266 and/or,
three, the end effector articulation driver 11268 is coupled to a
shaft articulation actuator 11248 configured to advance and retract
the end effector articulation driver 11268. In use, the firing
member 11266 can be advanced distally to move the anvil 11262 from
an open position in which tissue can be positioned intermediate the
anvil 11262 and the cartridge 11264 to a closed position in which
the anvil 11262 compresses the tissue against the cartridge 11264.
In various circumstances, the firing member 11266 can include a
first engagement member configured to engage the first jaw and a
second engagement member configured to engage the second jaw when
the firing member 11266 is advanced distally such that the anvil
11262 can be pivoted toward the staple cartridge 11264 by the
engagement members. In order to re-open the end effector and allow
the anvil 11262 to be returned to its open position, the firing
member 11266 must be sufficiently retracted. In various
circumstances, the firing member 11266 may become stuck in an at
least partially fired position and, as a result, the anvil 11262
may not be reopened thereby making the removal of the surgical
instrument from the surgical site difficult.
[0445] Turning now to FIGS. 156-161, an end effector, such as end
effector 11360, for example, can include a firing member which can
permit the anvil 11262 of the end effector 11360 to be re-opened
eventhough the firing member of the end effector 11360 is stuck in
an at least partially fired position. More particularly, the end
effector 11360 can include a firing member 11366 comprising
separable portions 11366a and 11366b which can be configured to
permit relative movement between the anvil 11262 and the cartridge
11264 in various instances. Referring primarily to FIGS. 157 and
158, the separable portions 11366a and 11366b can be held together
by a lock 11390 when the lock 11390 is in a locked condition, as
illustrated in FIG. 158. Correspondingly, when the lock 11390 is in
an unlocked condition, the separable portions 11366a and 11366b can
move relative to one another. The separable portion 11366a of the
firing member 11366 can comprise a first lateral portion 11363a, a
second lateral portion 11367a, and a cutting member portion 11365a
positioned intermediate the lateral portions 11363a and 11367a. In
various circumstances, the lateral portions 11363a and 11367a can
be retained to the cutting member portion 11365a via one or more
pins, not illustrated in FIGS. 157 and 158, extending through
apertures 11396a defined therein. The separable portion 11366b of
the firing member 11366 can comprise a first lateral portion
11363b, a second lateral portion 11367b, and a cutting member
portion 11365b positioned intermediate the lateral portions 11363b
and 11367b. In various circumstances, the lateral portions 11363b
and 11367b can be retained to the cutting member portion 11365b via
at least one retention member, not illustrated in FIGS. 157 and
158, engaged with a foot 11396b extending therefrom. As the reader
will appreciate, the aforementioned retention pins hold the various
components of the separable portion 11363a together while the
aforementioned retention member holds the various components of the
separable portion 11363b together. As the reader will also
appreciate, the lock 11390, when in its locked position, holds the
separable portions 11363a and 11363b together. In various
instances, referring primarily to FIG. 158, the lock 11390 can
include a first lock member 11397a configured to engage a first
lock portion 11361a of the first cutting member portion 11365a and,
in addition, a second lock member 11397b configured to engage a
second lock portion 11361b of the second cutting member portion
11365b. The first lock portion 11361a and the second lock portion
11361b can be configured to co-operatively and releasably hold the
cutting member portions 11365a and 11365b together. In various
instances, the lock portions 11397a, 11397b can hold the cutting
member portions 11365a and 11365b together such that cutting
surfaces 11395a and 11395b of the cutting member portions 11365a
and 11365b, respectively, form a continuous, or at least
substantially continuous, cutting surface. Referring once again to
FIG. 158, the lock portions 11397a, 11397b of the lock 11390 can be
configured to co-operatively engage and hold keys 11361a and 11361b
of cutting member portions 11365a and 11365b, respectively. In
various instances, the lock portions 11397a, 11397b can define a
recess 11398 therebetween which is configured to receive keys
11361a and 11361b when the lock 11390 is in its locked position.
When the lock 11390 is pulled proximally, the lock portions 11397a
and 11397b can disengage the keys 11361a and 11361b. At such point,
the lock 11390 may no longer hold the cutting member portions
11365a and 11365b together. In such circumstances, as a result, the
separable portions 11366a and 11366b can move relative to each
other. For instance, the separable portion 11366a can move with the
jaw 11262 when the jaw 11262 is re-opened and, correspondingly, the
separable portion 11366b can remain with the cartridge 11264. In
view of the above, the lock 11390 can be pulled proximally to
unlock the separable portions 11366a and 11366b when the firing
member 11366 becomes stuck in an at least partially fired position,
for example.
[0446] As discussed above, the lock 11390 can be pulled proximally
to unlock the separable portions 11366a and 11366b of the firing
member 11366. Turning now to FIG. 159, the lock 11390 can be pulled
proximally and/or pushed distally by lock bar 11391. The lock bar
11391 can be positioned within the end effector 11360 and can
include a proximal end 11392 and a distal end 11393. The distal end
11393 of the lock bar 11391 can be engaged with the lock 11390.
More specifically, in at least one embodiment, the distal end 11393
can include a projection extending therefrom which can be slidably
positioned within an elongate slot 11399 defined in the lock 11390.
In order to pull the lock 11390 proximally, the lock bar 11391 can
be pulled proximally until the projection contacts the proximal end
11394 of the elongate slot 11399 wherein the motion of the lock bar
11391 can be transferred to the lock 11390. Correspondingly, the
projection can be configured to contact a distal end 11395 of the
elongate slot 11399 in order to push the lock 11390 distally. As
the reader will appreciate, referring again to FIG. 156, the firing
member 11366 can one or more include longitudinal slots 11369
defined therein which can be configured to permit the lock bar
projection to extend therethrough and engage the lock 11390 as
described above.
[0447] Further to the above, referring primarily to FIGS. 156 and
160, the proximal end 11392 of the lock bar 11391 can comprise an
attachment portion configured to be engaged by a lock actuator
11348 of a shaft 11340 of a surgical instrument. Referring
primarily to FIG. 160, the lock actuator 11348 can comprise a
distal end 11349 including a notch, for example, which can be
configured to receive the proximal end 11392 of the lock bar 11391.
The lock actuator 11348 can further comprise a proximal end 11347
which can be pulled proximally and/or pushed distally by a user of
the surgical instrument in order to move the lock actuator 11348
and the lock bar 11391 proximally and/or distally, respectively. In
use, the proximal end 11392 of the lock bar 11391 can be assembled
to the distal end 11349 of the lock actuator 11348 when the end
effector 11360 is assembled to the shaft 11340.
[0448] As outlined above, a motor can be utilized to advance and/or
retract a firing member to deploy fasteners from an end effector
and/or incise tissue captured within the end effector. In various
instances, the motor can include a rotatable drive shaft, the
rotation of which can be converted to translational movement and
transmitted to a firing member, such as a cutting member and/or
staple driver, for example. In at least one such instance, the
rotatable drive shaft can include a threaded portion which is
threadably engaged with a collar including a threaded aperture
defined therein wherein, in use, the collar can be constrained from
rotating such that the rotation of the drive shaft advances the
collar distally and/or retracts the collar proximally depending on
the direction in which the drive shaft is rotated. In certain
instances, the firing member may become stuck and/or otherwise
experience a force, or torque, which exceeds a desired, or
predetermined maximum, force, or torque. Turning now to FIGS.
162-167, a motor assembly 12000 can include a motor 12010, a shaft
12020, and a slip clutch assembly 12030, wherein the slip clutch
assembly 12030 can limit the force, or torque, that the motor 12010
can transmit to the shaft 12020. In various instances, referring
primarily to FIGS. 162 and 163, the slip clutch assembly 12030 can
transmit torque between a rotatable drive output 12012 of the motor
12010 and the shaft 12020. Referring now to FIGS. 165-167, the
drive output 12012 can include a substantially circular outer
profile portion 12011 and a transition surface 12014, which can be
flat, or at least substantially flat, in various instances. The
outer profile of the drive output 12012 can further include a first
drive shoulder 12016 defined between the circular profile portion
12011 and the flat surface 12014 and, in addition, a second drive
shoulder 12018 which is defined between the opposite end of the
flat surface 12014 and the circular profile portion 12011.
[0449] As also illustrated in FIGS. 165-167, the slip clutch
assembly 12030 can include a drive element 12034 which is biased
into engagement with the drive output 12012 by a biasing element,
or spring, 12036. The drive element 12034 can be at least partially
positioned within a retention slot defined in a housing 12037 of
the slip clutch assembly 12030 such that the movement of the drive
element 12034 relative to the housing 12037 can be defined along an
axis. As the reader will appreciate, the housing 12037 of the slip
clutch assembly can be mounted to the shaft 12020 such that the
housing 12037 and the shaft 12020 rotate together synchronously. As
the reader will also appreciate, the drive element 12034 can
transmit the rotational motion of the drive output 12012 to the
housing 12037, at least in certain circumstances. More
specifically, when the drive output 12012 is rotated in a first
direction, as indicated by arrow 12017, to advance the firing
member distally, the drive output 12012 can rotate relative to the
drive element 12034 until the first drive shoulder 12016 comes into
contact with the drive element 12034. As the reader will
appreciate, the first drive shoulder 12016 can remain in contact
with the drive element 12034 so long as the biasing member 12036 is
able to resist, or at least sufficiently resist, the radially
outward movement of the drive element 12034. So long as the drive
element 12034 is in contact with the first drive shoulder 12016,
the motor 12010 can rotate the shaft 12020 in a direction which
advances the firing member distally. In various instances, the
motor 12010 may apply a torque to the drive output 12012 which is
large enough to displace the drive element 12034 radially outwardly
such that the first drive shoulder 12016 of the drive output 12012
slips by the drive element 12034 and, as a result, the drive output
12012 rotates relative to the drive element 12034, the slip clutch
housing 12037, and the shaft 12020. Stated another way, the drive
element 12034 can be defeated and operably disengaged from the
motor 12010 when the torque applied to the drive output 12012
exceeds a predetermined, or maximum, torque. When the torque
applied to the drive output 12012 falls below this predetermined,
or maximum, torque, the drive element 12034 can re-engage the first
drive shoulder 12016 and, as a result, the shaft 12020 can be
operably re-engaged with the motor 12010 such that the shaft 12020
is rotated by the drive output 12012 of the motor 12010.
[0450] Further to the above, when the drive output 12012 is rotated
in a second direction, as indicated by arrow 12019, to retract the
firing member proximally, the drive output 12012 can rotate
relative to the drive element 12034 until the second drive shoulder
12018 comes into contact with the drive element 12034. As the
reader will appreciate, the second drive shoulder 12018 can remain
in contact with the drive element 12034 so long as the biasing
member 12036 is able to resist, or at least sufficiently resist,
the radially outward movement of the drive element 12034. So long
as the drive element 12034 is in contact with the second drive
shoulder 12018, the motor 12010 can rotate the shaft 12020 in a
direction which retracts the firing member proximally. In various
instances, the motor 12010 may apply a torque to the drive output
12012 which is large enough to displace the drive element 12034
radially outwardly such that the second drive shoulder 12018 of the
drive output 12012 slips by the drive element 12034 and, as a
result, the drive output 12012 rotates relative to the drive
element 12034, the slip clutch housing 12037, and the shaft 12020.
Stated another way, the drive element 12034 can be defeated and
operably disengaged from the motor 12010 when the torque applied to
the drive output 12012 exceeds a predetermined, or maximum, torque.
When the torque applied to the drive output 12012 falls below this
predetermined, or maximum, torque, the drive element 12034 can
re-engage the second drive shoulder 12018 and, as a result, the
shaft 12020 can be operably re-engaged with the motor 12010 such
that the shaft 12020 is rotated by the drive output 12012 of the
motor 12010.
[0451] In various instances, further to the above, the first drive
shoulder 12016 and the second drive shoulder 12018 can comprise the
same configuration. In certain instances, the first drive shoulder
12016 can be defined by a first radius of curvature and the second
drive shoulder 12018 can be defined by a second radius of
curvature. In some instances, the first radius of curvature can be
the same as the second radius of curvature. In such instances, the
maximum, or slip, torque that the motor 12010 can apply when
rotating the drive output 12012 in the first direction 12017 can be
the same, or substantially the same, as the maximum, or slip,
torque that the motor 12010 can apply when rotating the drive
output 12012 in the second direction 12019. In some instances, the
first radius of curvature can be different than the second radius
of curvature. In such instances, the maximum, or slip, torque that
the motor 12010 can apply when rotating the drive output 12012 in
the first direction 12017 can be different than the maximum, or
slip, torque that the motor 12010 can apply when rotating the drive
output 12012 in the second direction 12019. In at least one such
instance, the first radius of curvature can be larger than the
second radius of curvature wherein, as a result, the maximum, or
slip, torque in the first direction 12017 can be less than the
maximum, or slip, torque in the second direction 12019. Stated
another way, the motor 12010 can apply a larger torque to the shaft
12020 when retracting the firing element than when advancing the
firing element. Such instances may be advantageous when it may be
desirable to retract the firing element so that the end effector of
the surgical instrument can be re-opened and unclamped from the
tissue, for example. In at least one instance, the first radius of
curvature can be smaller than the second radius of curvature
wherein, as a result, the maximum, or slip, torque in the first
direction 12017 can be greater than the maximum, or slip, torque in
the second direction 12019. Stated another way, the motor 12010 can
apply a larger torque to the shaft 12020 when advancing the firing
element than when retracting the firing element.
[0452] Further to the above, referring primarily to FIGS. 163 and
164, the biasing member 12036 can be resiliently supported by a
spring collar 12032 positioned within a circumferential channel
12031 defined in the slip clutch housing 12037. In such instances,
the spring collar 12032 and the biasing member 12036 can co-operate
to apply a radially inward biasing force and/or to resist the
radially outward movement of the drive element 12034. The spring
collar 12032, in various instances, can comprise an annular body
including a first free end 12033 and a second free end 12034,
wherein the annular body can resiliently expand when the radially
outward force discussed above is applied thereto and resiliently
contract when that radially outward force has ceased or diminished.
In such instances, the first free end 12033 of the spring collar
12032 can move relative to the second free end 12034.
[0453] 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.
[0454] 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.
[0455] 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.
[0456] While this invention has been described as having exemplary
designs, the present invention may be further modified within the
spirit and scope of the disclosure. This application is therefore
intended to cover any variations, uses, or adaptations of the
invention using its general principles. Further, this application
is intended to cover such departures from the present disclosure as
come within known or customary practice in the art to which this
invention pertains.
* * * * *