U.S. patent application number 14/226094 was filed with the patent office on 2015-10-01 for verification of number of battery exchanges/procedure count.
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 Shane R. Adams, Kevin L. Houser, Richard L. Leimbach, Thomas W. Lytle, IV, Mark D. Overmyer, Frederick E. Shelton, IV, Brett E. Swensgard.
Application Number | 20150272580 14/226094 |
Document ID | / |
Family ID | 55307121 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150272580 |
Kind Code |
A1 |
Leimbach; Richard L. ; et
al. |
October 1, 2015 |
VERIFICATION OF NUMBER OF BATTERY EXCHANGES/PROCEDURE COUNT
Abstract
The present disclosure provides a power assembly including a
housing configured to couple to a surgical instrument. The housing
includes at least two electrical contacts. A power source is
coupled to the at least two electrical contacts. The power source
is configured to provide power to the surgical instrument and a
usage cycle circuit is configured to monitor one or more conditions
of the power assembly and maintain a usage cycle count.
Inventors: |
Leimbach; Richard L.;
(Cincinnati, OH) ; Adams; Shane R.; (Lebanon,
OH) ; Overmyer; Mark D.; (Cincinnati, OH) ;
Swensgard; Brett E.; (West Chester, OH) ; Lytle, IV;
Thomas W.; (Liberty Township, OH) ; Shelton, IV;
Frederick E.; (Hillsboro, OH) ; Houser; Kevin L.;
(Springboro, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ethicon Endo-Surgery, Inc. |
Cincinnati |
OH |
US |
|
|
Assignee: |
Ethicon Endo-Surgery, Inc.
Cincinnati
OH
|
Family ID: |
55307121 |
Appl. No.: |
14/226094 |
Filed: |
March 26, 2014 |
Current U.S.
Class: |
227/175.1 ;
307/150 |
Current CPC
Class: |
A61L 2/26 20130101; A61B
17/068 20130101; A61B 2017/00221 20130101; A61B 2017/00734
20130101; A61B 2017/00199 20130101; A61B 2090/0808 20160201; A61B
90/98 20160201; A61L 2/206 20130101; A61B 2017/00725 20130101; A61L
2/07 20130101; A61L 2/16 20130101; A61L 2202/24 20130101; H01M
2010/4278 20130101; H02J 7/007192 20200101; A61B 2017/2927
20130101; A61B 2017/2929 20130101; H02J 5/00 20130101; A61B
2017/00017 20130101; H02J 7/0047 20130101; A61B 2017/07285
20130101; A61B 2017/2912 20130101; A61L 2/082 20130101; A61L 2/087
20130101; H02J 7/0048 20200101; H01R 39/10 20130101; A61B 90/06
20160201; A61B 2017/00212 20130101; A61B 17/07207 20130101; A61B
34/76 20160201; A61B 2034/302 20160201; A61B 2090/0813 20160201;
H02J 7/027 20130101; A61B 18/1445 20130101; A61B 2017/00119
20130101; A61B 2090/0807 20160201; B25F 3/00 20130101; H01R 39/08
20130101; A61B 2090/0803 20160201; A61B 2017/00407 20130101; A61B
2017/00464 20130101; A61L 2/081 20130101; A61B 2017/00137 20130101;
H01R 39/64 20130101; H02J 7/007188 20200101; H02J 7/02 20130101;
Y02E 60/10 20130101; A61B 17/320016 20130101; A61B 2017/00115
20130101; H01R 35/025 20130101; H01R 2201/12 20130101; A61B
2017/0046 20130101; A61B 2017/07278 20130101; H01M 10/425 20130101;
A61B 2017/00477 20130101; A61B 2090/0814 20160201; A61B 2017/00123
20130101; H01M 2220/30 20130101; A61B 2090/065 20160201; A61B
2090/081 20160201; A61B 2090/0811 20160201; A61B 90/90 20160201;
A61B 2017/00225 20130101; A61B 2017/00398 20130101; B25F 5/00
20130101; A61B 2017/00084 20130101; A61B 2017/07271 20130101; A61L
2202/14 20130101; A61B 17/0686 20130101; H01M 2/1055 20130101; H01M
10/48 20130101 |
International
Class: |
A61B 17/072 20060101
A61B017/072; A61L 2/20 20060101 A61L002/20; H02J 7/02 20060101
H02J007/02; A61B 19/00 20060101 A61B019/00 |
Claims
1. A power assembly, comprising: a housing configured to couple to
a surgical instrument, the housing comprising at least two
electrical contacts; a power source coupled to the at least two
electrical contacts, wherein the power source is configured to
provide power to the surgical instrument; and a usage cycle circuit
configured to monitor one or more conditions of the power assembly
and maintain a usage cycle count.
2. The power assembly of claim 1, wherein the usage cycle circuit
comprises: a processor to maintain the usage cycle count; and a use
indicator in signal communication with the processor, wherein the
use indicator is configured to detect the one or more conditions of
the power assembly, and wherein the processor is configured to
modify the usage cycle count when the use indicator detects the one
or more conditions.
3. The power assembly of claim 2, wherein the use indicator
comprises a timing circuit configured to monitor a single patient
procedure time.
4. The power assembly of claim 3, wherein the use indicator
comprises a resistor-capacitor circuit having a time constant
corresponding to the single patient procedure time, and wherein the
processor is configured to detect an electrical parameter of the
resistor-capacitor circuit, and wherein the electrical parameter
being below a predetermined threshold indicates that the single
patient procedure time has elapsed.
5. The power assembly of claim 4, comprising a transistor coupled
to the power source, the processor, and the resistor-capacitor
circuit, wherein the processor is configured to control the
transistor as a switch, and wherein the processor closes the
transistor to charge the resistor-capacitor circuit when the
electrical parameter is below the predetermined threshold.
6. The power assembly of claim 3, wherein the use indicator
comprises: a rechargeable clock battery; and a clock in signal
communication with the rechargeable clock battery and the
processor, wherein the rechargeable clock battery comprises a
maximum voltage sufficient to run the clock for at least the single
patient procedure time, and wherein the processor modifies the
usage cycle count when the clock indicates that a time period
corresponding to the single patient procedure time has elapsed.
7. The power assembly of claim 6, comprising a transistor coupled
to the power source, the processor, and the rechargeable clock
battery, wherein the processor is configured to control the
transistor as a switch, and wherein the processor closes the
transistor to charge the rechargeable clock battery when the single
patient procedure time has elapsed.
8. The power assembly of claim 2, wherein the use indicator is
configured to detect a recharging cycle of the power assembly.
9. The power assembly of claim 2, wherein the usage cycle circuit
is configured to disable operation of the power assembly when the
usage cycle count is equal to a predetermined usage limit.
10. The power assembly of claim 9, wherein the processor is
configured to increment the usage cycle count when the use
indicator detects the one or more conditions of the power
assembly.
11. The power assembly of claim 2, wherein the one or more
conditions of the power assembly comprise environmental
conditions.
12. The power assembly of claim 11, wherein the use indicator
comprises an accelerometer, and wherein the processor is configured
to modify the usage cycle count when the accelerometer indicates an
acceleration above a predetermined threshold.
13. The power assembly of claim 11, wherein the use indicator
comprises a chemical sensor, and wherein the processor is
configured to modify the usage cycle count when the chemical sensor
is configured to detect one or more predetermined chemicals.
14. The power assembly of claim 2, wherein the usage cycle circuit
comprises a counter configured to maintain the usage cycle
count.
15. The power assembly of claim 14, wherein the counter comprises a
memory module in signal communication with the processor.
16. The power assembly of claim 14, wherein the counter comprises a
resistor pack in signal communication with the processor, wherein
the processor is configured to disable one or more resistors of the
resistor pack when the use indicator is configured to detect the
one or more conditions of the power assembly.
17. The power assembly of claim 2, comprising a communications
module configured to transmit the usage cycle count a remote
system.
18. The power assembly of claim 17, wherein the communications
module is configured to receive one or more instructions from the
remote system.
19. A surgical instrument comprising: a handle assembly comprising:
a usage cycle circuit configured to monitor one or more conditions
of the surgical instrument and maintain a usage cycle count a
removable power assembly; and a modular shaft comprising a proximal
end and a distal end, wherein the module shaft is detachably
coupled to the handle assembly at the proximal end; and an end
effector coupled to the distal end of the modular shaft.
20. The surgical instrument of claim 19, wherein the usage cycle
circuit comprises: a processor to maintain the usage cycle count;
and a use indicator in signal communication with the processor,
wherein the use indicator is configured to detect the one or more
conditions of the surgical instrument, and wherein the processor is
configured to modify the usage cycle count when the use indicator
detects the one or more conditions.
21. The surgical instrument of claim 20, wherein the use indicator
comprises a timing circuit configured to monitor a single patient
procedure time.
22. The surgical instrument of claim 21, wherein the use indicator
comprises a resistor-capacitor circuit having a time constant
corresponding to the single patient procedure time, and wherein the
processor is configured to detect an electrical parameter of the
resistor-capacitor circuit, and wherein the electrical parameter
being below a predetermined threshold indicates that the single
patient procedure time has elapsed.
23. The surgical instrument of claim 22, comprising a transistor
coupled to the power source, the processor, and the
resistor-capacitor circuit, wherein the processor is configured to
control the transistor as a switch, and wherein the processor is
configured to close the transistor to charge the resistor-capacitor
circuit when the electrical parameter is below the predetermined
threshold.
24. The surgical instrument of claim 21, wherein the use indicator
comprises: a rechargeable clock battery; and a clock in signal
communication with the rechargeable clock battery and the
processor, wherein the rechargeable clock battery comprises a
maximum voltage sufficient to run the clock for at least the single
patient procedure time, and wherein the processor is configured to
modify the usage cycle count when the clock indicates that a time
period corresponding to the single patient procedure time has
elapsed.
25. The surgical instrument of claim 24, comprising a transistor
coupled to the power source, the processor, and the rechargeable
clock battery, wherein the processor is configured to control the
transistor as a switch, and wherein the processor is configured to
close the transistor to charge the rechargeable clock battery when
the single patient procedure time has elapsed.
26. The surgical instrument of claim 20, wherein the use indicator
is configured to detect a recharging cycle of the power
assembly.
27. The surgical instrument of claim 20, wherein the usage cycle
circuit is configured to disable operation of the surgical
instrument when the usage cycle count is equal to a predetermined
usage limit.
28. The surgical instrument of claim 27, wherein the processor is
configured to increment the usage cycle count when the use
indicator detects the one or more conditions of the power
assembly.
29. The surgical instrument of claim 20, wherein the one or more
conditions of the surgical instrument comprise environmental
conditions.
30. The surgical instrument of claim 29, wherein the use indicator
comprises an accelerometer, and wherein the processor is configured
to modify the usage cycle count when the accelerometer indicates an
acceleration above a predetermined threshold.
31. The surgical instrument of claim 29, wherein the use indicator
comprises a chemical sensor, and wherein the processor is
configured to modify the usage cycle count when the chemical sensor
detects one or more predetermined chemicals.
32. The surgical instrument of claim 20, wherein the usage cycle
circuit comprises a counter configured to maintain the usage cycle
count.
33. The surgical instrument of claim 32, wherein the counter
comprises a memory module in signal communication with the
processor.
34. The surgical instrument of claim 32, wherein the counter
comprises a resistor pack in signal communication with the
processor, wherein the processor is configured to disable one or
more resistors of the resistor pack when the use indicator is
configured to detect the one or more conditions of the power
assembly.
35. The surgical instrument of claim 20, comprising a
communications module configured to transmit the usage cycle count
a remote system.
36. The surgical instrument of claim 35, wherein the communications
module is configured to receive one or more instructions from the
remote system.
37. The surgical instrument of claim 20, wherein the one or more
conditions of the surgical instrument comprise inserting a staple
cartridge into the end effector.
38. The surgical instrument of claim 20, wherein the one or more
conditions of the surgical instrument comprise firing of the
surgical instrument.
39. The surgical instrument of claim 20, comprising a display,
wherein the display is configured to display the usage cycle
count.
40. A sterilization system configured to sterilize a surgical
instrument, the sterilization system comprising: a sterilization
chamber configured to receive a power assembly, the sterilization
chamber comprising a charging cable mounted through a wall of the
sterilization chamber, wherein the charging cable is sealed such
that the sterilization chamber integrity is maintained; and wherein
the sterilization system is configured to charge the power assembly
during a sterilization cycle.
41. The sterilization system of claim 40, comprising a sensor
located within the sterilization chamber, the sensor configured to
monitor the power assembly during a charging and sterilization
cycle.
42. The sterilization system of claim 41, wherein the sensor
comprises a sensor cable mounted through the wall of the
sterilization chamber.
43. The sterilization system of claim 41, wherein the sensor is
configured to monitor the charge level of the power assembly.
44. The sterilization system of claim 41, wherein the sensor is
configured to monitor the temperature of the power assembly.
45. The sterilization system of claim 41, wherein the sensor is
configured to monitor an amount of H.sub.2O.sub.2 present in the
sterilization chamber.
46. The sterilization system of claim 40, wherein the charging
cable comprises an alternating current input, wherein the power
assembly comprises an alternating current charging circuit integral
therewith, and wherein the alternating current charging circuit is
coupled to the alternating current input when the power assembly is
placed in the sterilization chamber.
47. The sterilization system of claim 40, wherein the charging
cable comprises a battery connector at a first end located within
the sterilization chamber and wherein the charging cable is coupled
to a battery charger at a second end located outside of the
sterilization chamber.
Description
BACKGROUND
[0001] The present invention relates to surgical instruments and,
in various circumstances, to surgical stapling and cutting
instruments and staple cartridges therefor that are designed to
staple and cut tissue.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] The features and advantages of this invention, and the
manner of attaining them, will become more apparent and the
invention itself will be better understood by reference to the
following description of embodiments of the invention taken in
conjunction with the accompanying drawings, wherein:
[0003] FIG. 1 is a perspective view of a surgical instrument that
has an interchangeable shaft assembly operably coupled thereto;
[0004] FIG. 2 is an exploded assembly view of the interchangeable
shaft assembly and surgical instrument of FIG. 1;
[0005] FIG. 3 is another exploded assembly view showing portions of
the interchangeable shaft assembly and surgical instrument of FIGS.
1 and 2;
[0006] FIG. 4 is an exploded assembly view of a portion of the
surgical instrument of FIGS. 1-3;
[0007] FIG. 5 is a cross-sectional side view of a portion of the
surgical instrument of FIG. 4 with the firing trigger in a fully
actuated position;
[0008] FIG. 6 is another cross-sectional view of a portion of the
surgical instrument of FIG. 5 with the firing trigger in an
unactuated position;
[0009] FIG. 7 is an exploded assembly view of one form of an
interchangeable shaft assembly;
[0010] FIG. 8 is another exploded assembly view of portions of the
interchangeable shaft assembly of FIG. 7;
[0011] FIG. 9 is another exploded assembly view of portions of the
interchangeable shaft assembly of FIGS. 7 and 8;
[0012] FIG. 10 is a cross-sectional view of a portion of the
interchangeable shaft assembly of FIGS. 7-9;
[0013] FIG. 11 is a perspective view of a portion of the shaft
assembly of FIGS. 7-10 with the switch drum omitted for
clarity;
[0014] FIG. 12 is another perspective view of the portion of the
interchangeable shaft assembly of FIG. 11 with the switch drum
mounted thereon;
[0015] FIG. 13 is a perspective view of a portion of the
interchangeable shaft assembly of FIG. 11 operably coupled to a
portion of the surgical instrument of FIG. 1 illustrated with the
closure trigger thereof in an unactuated position;
[0016] FIG. 14 is a right side elevational view of the
interchangeable shaft assembly and surgical instrument of FIG.
13;
[0017] FIG. 15 is a left side elevational view of the
interchangeable shaft assembly and surgical instrument of FIGS. 13
and 14;
[0018] FIG. 16 is a perspective view of a portion of the
interchangeable shaft assembly of FIG. 11 operably coupled to a
portion of the surgical instrument of FIG. 1 illustrated with the
closure trigger thereof in an actuated position and a firing
trigger thereof in an unactuated position;
[0019] FIG. 17 is a right side elevational view of the
interchangeable shaft assembly and surgical instrument of FIG.
16;
[0020] FIG. 18 is a left side elevational view of the
interchangeable shaft assembly and surgical instrument of FIGS. 16
and 17;
[0021] FIG. 18A is a right side elevational view of the
interchangeable shaft assembly of FIG. 11 operably coupled to a
portion of the surgical instrument of FIG. 1 illustrated with the
closure trigger thereof in an actuated position and the firing
trigger thereof in an actuated position;
[0022] FIG. 19 is a perspective view of a portion of an
interchangeable shaft assembly showing an electrical coupler
arrangement;
[0023] FIG. 20 is an exploded assembly view of portions of the
interchangeable shaft assembly and electrical coupler of FIG.
19;
[0024] FIG. 21 is a perspective view of circuit trace assembly;
[0025] FIG. 22 is a plan view of a portion of the circuit trace
assembly of FIG. 21;
[0026] FIG. 23 is a perspective view of a portion of another
interchangeable shaft assembly showing another electrical coupler
arrangement;
[0027] FIG. 24 is an exploded assembly view of portions of the
interchangeable shaft assembly and electrical coupler of FIG.
23;
[0028] FIG. 25 is an exploded slip ring assembly of the electrical
coupler of FIGS. 23 and 24;
[0029] FIG. 26 is a perspective view of a portion of another
interchangeable shaft assembly showing another electrical coupler
arrangement;
[0030] FIG. 27 is an exploded assembly view of portions of the
interchangeable shaft assembly and electrical coupler of FIG.
26;
[0031] FIG. 28 is a front perspective view of a portion of the slip
ring assembly of the electrical coupler of FIGS. 26 and 27;
[0032] FIG. 29 is an exploded assembly view of the slip ring
assembly portion of FIG. 28; and
[0033] FIG. 30 is a rear perspective view of the portion of slip
ring assembly of FIGS. 28 and 29.
[0034] FIG. 31 is a perspective view of a surgical instrument
comprising a power assembly, a handle assembly, and an
interchangeable shaft assembly;
[0035] FIG. 32 is perspective view of the surgical instrument of
FIG. 31 with the interchangeable shaft assembly separated from the
handle assembly;
[0036] FIG. 33, which is divided into FIGS. 33A and 33B, is a
circuit diagram of the surgical instrument of FIG. 31;
[0037] FIG. 34 is a block diagram of interchangeable shaft
assemblies for use with the surgical instrument of FIG. 31;
[0038] FIG. 35 is a perspective view of the power assembly of the
surgical instrument of FIG. 31 separated from the handle
assembly;
[0039] FIG. 36 is a block diagram the surgical instrument of FIG.
31 illustrating interfaces between the handle assembly and the
power assembly and between the handle assembly and the
interchangeable shaft assembly;
[0040] FIG. 37 is a power management module of the surgical
instrument of FIG. 31;
[0041] FIG. 38 is a perspective view of a surgical instrument
comprising a power assembly and an interchangeable working assembly
assembled with the power assembly;
[0042] FIG. 39 is a block diagram of the surgical instrument of
FIG. 38 illustrating an interface between the interchangeable
working assembly and the power assembly;
[0043] FIG. 40 is a block diagram illustrating a module of the
surgical instrument of FIG. 38;
[0044] FIG. 41 is a perspective view of a surgical instrument
comprising a power assembly and a interchangeable working assembly
assembled with the power assembly;
[0045] FIG. 42 is a circuit diagram of an exemplary power assembly
of the surgical instrument of FIG. 41;
[0046] FIG. 43 is a circuit diagram of an exemplary power assembly
of the surgical instrument of FIG. 41;
[0047] FIG. 44 is a circuit diagram of an exemplary interchangeable
working assembly of the surgical instrument of FIG. 41;
[0048] FIG. 45 is a circuit diagram of an exemplary interchangeable
working assembly of the surgical instrument of FIG. 41;
[0049] FIG. 46 is a block diagram depicting an exemplary module of
the surgical instrument of FIG. 41;
[0050] FIG. 47A is a graphical representation of an exemplary
communication signal generated by a working assembly controller of
the interchangeable working assembly of the surgical instrument of
FIG. 41 as detected by a voltage monitoring mechanism;
[0051] FIG. 47B is a graphical representation of an exemplary
communication signal generated by a working assembly controller of
the interchangeable working assembly of the surgical instrument of
FIG. 41 as detected by a current monitoring mechanism; and
[0052] FIG. 47C is a graphical representation of effective motor
displacement of a motor of the interchangeable working assembly of
FIG. 41 in response to the communication signal generated by the
working assembly controller of FIG. 47A.
[0053] FIG. 48 is a perspective view of a surgical instrument
comprising a handle assembly and a shaft assembly including an end
effector;
[0054] FIG. 49 is a perspective view of the handle assembly of the
surgical instrument of FIG. 48;
[0055] FIG. 50 is an exploded view of the handle assembly of the
surgical instrument of FIG. 48;
[0056] FIG. 51 is a schematic diagram of a bailout feedback system
of the surgical instrument of FIG. 48;
[0057] FIG. 52 is a block diagram of a module for use with the
bailout feedback system of FIG. 51;
[0058] FIG. 53 is a block diagram of a module for use with the
bailout feedback system of FIG. 51,
[0059] FIG. 54 illustrates one instance of a power assembly
comprising a usage cycle circuit configured to generate a usage
cycle count of the battery back;
[0060] FIG. 55 illustrates one instance of a usage cycle circuit
comprising a resistor-capacitor timer;
[0061] FIG. 56 illustrates one instance of a usage cycle circuit
comprising a timer and a rechargeable battery;
[0062] FIG. 57 illustrates one instance of a combination
sterilization and charging system configured to sterilize and
charge a power assembly simultaneously;
[0063] FIG. 58 illustrates one instance of a combination
sterilization and charging system configured to sterilize and
charge a power assembly having a battery charger formed integrally
therein;
[0064] FIG. 59 is a schematic of a system for powering down an
electrical connector of a surgical instrument handle when a shaft
assembly is not coupled thereto;
[0065] FIG. 60 is a flowchart depicting a method for adjusting the
velocity of a firing element according to various embodiments of
the present disclosure;
[0066] FIG. 61 is a flowchart depicting a method for adjusting the
velocity of a firing element according to various embodiments of
the present disclosure;
[0067] FIG. 62 is a partial, perspective view of an end effector
and a fastener cartridge according to various embodiments of the
present disclosure;
[0068] FIG. 63 is partial, perspective view of an end effector and
a fastener cartridge according to various embodiments of the
present disclosure;
[0069] FIG. 64 is a cross-sectional, elevation view of an end
effector and a fastener cartridge according to various embodiments
of the present disclosure;
[0070] FIG. 65 is a cross-sectional, elevation view of an end
effector and a fastener cartridge according to various embodiments
of the present disclosure;
[0071] FIG. 66 is a partial, perspective view of an end effector
with portions removed and a fastener cartridge according to various
embodiments of the present disclosure;
[0072] FIG. 67 is a partial, perspective view of an end effector
with portions removed and a fastener cartridge according to various
embodiments of the present disclosure;
[0073] FIG. 68(A) is a schematic depicting an integrated circuit
according to various embodiments of the present disclosure;
[0074] FIG. 68(B) is a schematic depicting a magnetoresistive
circuit according to various embodiments of the present disclosure;
and
[0075] FIG. 68(C) is a table listing various specifications of a
magnetoresistive sensor according to various embodiments of the
present disclosure.
DETAILED DESCRIPTION
[0076] Applicant of the present application owns the following
patent applications that were filed on Mar. 1, 2013 and which are
each herein incorporated by reference in their respective
entireties: [0077] U.S. patent application Ser. No. 13/782,295,
entitled ARTICULATABLE SURGICAL INSTRUMENTS WITH CONDUCTIVE
PATHWAYS FOR SIGNAL COMMUNICATION; [0078] U.S. patent application
Ser. No. 13/782,323, entitled ROTARY POWERED ARTICULATION JOINTS
FOR SURGICAL INSTRUMENTS; [0079] U.S. patent application Ser. No.
13/782,338, entitled THUMBWHEEL SWITCH ARRANGEMENTS FOR SURGICAL
INSTRUMENTS; [0080] U.S. patent application Ser. No. 13/782,499,
entitled ELECTROMECHANICAL SURGICAL DEVICE WITH SIGNAL RELAY
ARRANGEMENT; [0081] U.S. patent application Ser. No. 13/782,460,
entitled MULTIPLE PROCESSOR MOTOR CONTROL FOR MODULAR SURGICAL
INSTRUMENTS; [0082] U.S. patent application Ser. No. 13/782,358,
entitled JOYSTICK SWITCH ASSEMBLIES FOR SURGICAL INSTRUMENTS;
[0083] U.S. patent application Ser. No. 13/782,481, entitled SENSOR
STRAIGHTENED END EFFECTOR DURING REMOVAL THROUGH TROCAR; [0084]
U.S. patent application Ser. No. 13/782,518, entitled CONTROL
METHODS FOR SURGICAL INSTRUMENTS WITH REMOVABLE IMPLEMENT PORTIONS;
[0085] U.S. patent application Ser. No. 13/782,375, entitled ROTARY
POWERED SURGICAL INSTRUMENTS WITH MULTIPLE DEGREES OF FREEDOM; and
[0086] U.S. patent application Ser. No. 13/782,536, entitled
SURGICAL INSTRUMENT SOFT STOP are hereby incorporated by reference
in their entireties.
[0087] Applicant of the present application also owns the following
patent applications that were filed on Mar. 14, 2013 and which are
each herein incorporated by reference in their respective
entireties: [0088] U.S. patent application Ser. No. 13/803,097,
entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING
DRIVE; [0089] U.S. patent application Ser. No. 13/803,193, entitled
CONTROL ARRANGEMENTS FOR A DRIVE MEMBER OF A SURGICAL INSTRUMENT;
[0090] U.S. patent application Ser. No. 13/803,053, entitled
INTERCHANGEABLE SHAFT ASSEMBLIES FOR USE WITH A SURGICAL
INSTRUMENT; [0091] U.S. patent application Ser. No. 13/803,086,
entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN
ARTICULATION LOCK; [0092] U.S. patent application Ser. No.
13/803,210, entitled SENSOR ARRANGEMENTS FOR ABSOLUTE POSITIONING
SYSTEM FOR SURGICAL INSTRUMENTS; [0093] U.S. patent application
Ser. No. 13/803,148, entitled MULTI-FUNCTION MOTOR FOR A SURGICAL
INSTRUMENT; [0094] U.S. patent application Ser. No. 13/803,066,
entitled DRIVE SYSTEM LOCKOUT ARRANGEMENTS FOR MODULAR SURGICAL
INSTRUMENTS; [0095] U.S. patent application Ser. No. 13/803,117,
entitled ARTICULATION CONTROL SYSTEM FOR ARTICULATABLE SURGICAL
INSTRUMENTS; [0096] U.S. patent application Ser. No. 13/803,130,
entitled DRIVE TRAIN CONTROL ARRANGEMENTS FOR MODULAR SURGICAL
INSTRUMENTS; and [0097] U.S. patent application Ser. No.
13/803,159, entitled METHOD AND SYSTEM FOR OPERATING A SURGICAL
INSTRUMENT.
[0098] Applicant of the present application also owns the following
patent applications that were filed on even date herewith and are
each herein incorporated by reference in their respective
entireties:
[0099] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT COMPRISING A SENSOR SYSTEM, Attorney Docket No.
END7386USNP/130458;
[0100] U.S. patent application Ser. No. ______, entitled POWER
MANAGEMENT CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, Attorney
Docket No. END7387USNP/130459;
[0101] U.S. patent application Ser. No. ______, entitled
STERILIZATION VERIFICATION CIRCUIT, Attorney Docket No.
END7388USNP/130460;
[0102] U.S. patent application Ser. No. ______, entitled POWER
MANAGEMENT THROUGH SLEEP OPTIONS OF SEGMENTED CIRCUIT AND WAKE UP
CONTROL, Attorney Docket No. END7390USNP/130462;
[0103] U.S. patent application Ser. No. ______, entitled MODULAR
POWERED SURGICAL INSTRUMENT WITH DETACHABLE SHAFT ASSEMBLIES,
Attorney Docket No. END7391USNP/130463;
[0104] U.S. patent application Ser. No. ______, entitled FEEDBACK
ALGORITHMS FOR MANUAL BAILOUT SYSTEMS FOR SURGICAL INSTRUMENTS,
Attorney Docket No. END7392USNP/130464;
[0105] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT UTILIZING SENSOR ADAPTATION, Attorney Docket No.
END7393USNP/130465;
[0106] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT CONTROL CIRCUIT HAVING A SAFETY PROCESSOR, Attorney
Docket No. END7394USNP/130466;
[0107] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT COMPRISING INTERACTIVE SYSTEMS, Attorney Docket No.
END7395USNP/130467;
[0108] U.S. patent application Ser. No. ______, entitled INTERFACE
SYSTEMS FOR USE WITH SURGICAL INSTRUMENTS, Attorney Docket No.
END7396USNP/130468;
[0109] U.S. patent application Ser. No. ______, entitled MODULAR
SURGICAL INSTRUMENT SYSTEM, Attorney Docket No.
END7397USNP/130469;
[0110] U.S. patent application Ser. No. ______, entitled SYSTEMS
AND METHODS FOR CONTROLLING A SEGMENTED CIRCUIT, Attorney Docket
No. END7399USNP/130471;
[0111] U.S. patent application Ser. No. ______, entitled POWER
MANAGEMENT THROUGH SEGMENTED CIRCUIT AND VARIABLE VOLTAGE
PROTECTION, Attorney Docket No. END7400USNP/130472;
[0112] U.S. patent application Ser. No. ______, entitled SURGICAL
STAPLING INSTRUMENT SYSTEM, Attorney Docket No. END7401USNP/130473;
and
[0113] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT COMPRISING A ROTATABLE SHAFT, Attorney Docket No.
END7402USNP/130474.
[0114] 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. 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.
[0115] Reference throughout the specification to "various
embodiments," "some embodiments," "one embodiment," or "an
embodiment", or the like, means that a particular feature,
structure, or characteristic described in connection with the
embodiment is included in at least one embodiment. Thus,
appearances of the phrases "in various embodiments," "in some
embodiments," "in one embodiment", or "in an embodiment", or the
like, in places throughout the specification are not necessarily
all referring to the same embodiment. Furthermore, the particular
features, structures, or characteristics may be combined in any
suitable manner in one or more embodiments. Thus, the particular
features, structures, or characteristics illustrated or described
in connection with one embodiment may be combined, in whole or in
part, with the features structures, or characteristics of one or
more other embodiments without limitation. Such modifications and
variations are intended to be included within the scope of the
present invention.
[0116] 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.
[0117] 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.
[0118] FIGS. 1-6 depict a motor-driven surgical cutting and
fastening instrument 10 that may or may not be reused. In the
illustrated embodiment, the instrument 10 includes a housing 12
that comprises a handle 14 that is configured to be grasped,
manipulated and actuated by the clinician. The housing 12 is
configured for operable attachment to an interchangeable shaft
assembly 200 that has a surgical end effector 300 operably coupled
thereto that is configured to perform one or more surgical tasks or
procedures. As the present Detailed Description proceeds, it will
be understood that the various unique and novel arrangements of the
various forms of interchangeable shaft assemblies disclosed herein
may also be effectively employed in connection with
robotically-controlled surgical systems. Thus, the term "housing"
may also encompass a housing or similar portion of a robotic system
that houses or otherwise operably supports at least one drive
system that is configured to generate and apply at least one
control motion which could be used to actuate the interchangeable
shaft assemblies disclosed herein and their respective equivalents.
The term "frame" may refer to a portion of a handheld surgical
instrument. The term "frame" may also represent a portion of a
robotically controlled surgical instrument and/or a portion of the
robotic system that may be used to operably control a surgical
instrument. For example, the interchangeable shaft assemblies
disclosed herein may be employed with various robotic systems,
instruments, components and methods disclosed in U.S. patent
application Ser. No. 13/118,241, entitled SURGICAL STAPLING
INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.
Patent Application Publication No. US 2012/0298719. U.S. patent
application Ser. No. 13/118,241, entitled SURGICAL STAPLING
INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.
Patent Application Publication No. US 2012/0298719, is incorporated
by reference herein in its entirety.
[0119] The housing 12 depicted in FIGS. 1-3 is shown in connection
with an interchangeable shaft assembly 200 that includes an end
effector 300 that comprises a surgical cutting and fastening device
that is configured to operably support a surgical staple cartridge
304 therein. The housing 12 may be configured for use in connection
with interchangeable shaft assemblies that include end effectors
that are adapted to support different sizes and types of staple
cartridges, have different shaft lengths, sizes, and types, etc. In
addition, the housing 12 may also be effectively employed with a
variety of other interchangeable shaft assemblies including those
assemblies that are configured to apply other motions and forms of
energy such as, for example, radio frequency (RF) energy,
ultrasonic energy and/or motion to end effector arrangements
adapted for use in connection with various surgical applications
and procedures. Furthermore, the end effectors, shaft assemblies,
handles, surgical instruments, and/or surgical instrument systems
can utilize any suitable fastener, or fasteners, to fasten tissue.
For instance, a fastener cartridge comprising a plurality of
fasteners removably stored therein can be removably inserted into
and/or attached to the end effector of a shaft assembly.
[0120] FIG. 1 illustrates the surgical instrument 10 with an
interchangeable shaft assembly 200 operably coupled thereto. FIGS.
2 and 3 illustrate attachment of the interchangeable shaft assembly
200 to the housing 12 or handle 14. As can be seen in FIG. 4, the
handle 14 may comprise a pair of interconnectable handle housing
segments 16 and 18 that may be interconnected by screws, snap
features, adhesive, etc. In the illustrated arrangement, the handle
housing segments 16, 18 cooperate to form a pistol grip portion 19
that can be gripped and manipulated by the clinician. As will be
discussed in further detail below, the handle 14 operably supports
a plurality of drive systems therein that are configured to
generate and apply various control motions to corresponding
portions of the interchangeable shaft assembly that is operably
attached thereto.
[0121] Referring now to FIG. 4, the handle 14 may further include a
frame 20 that operably supports a plurality of drive systems. For
example, the frame 20 can operably support a "first" or closure
drive system, generally designated as 30, which may be employed to
apply closing and opening motions to the interchangeable shaft
assembly 200 that is operably attached or coupled thereto. In at
least one form, the closure drive system 30 may include an actuator
in the form of a closure trigger 32 that is pivotally supported by
the frame 20. More specifically, as illustrated in FIG. 4, the
closure trigger 32 is pivotally coupled to the housing 14 by a pin
33. Such arrangement enables the closure trigger 32 to be
manipulated by a clinician such that when the clinician grips the
pistol grip portion 19 of the handle 14, the closure trigger 32 may
be easily pivoted from a starting or "unactuated" position to an
"actuated" position and more particularly to a fully compressed or
fully actuated position. The closure trigger 32 may be biased into
the unactuated position by spring or other biasing arrangement (not
shown). In various forms, the closure drive system 30 further
includes a closure linkage assembly 34 that is pivotally coupled to
the closure trigger 32. As can be seen in FIG. 4, the closure
linkage assembly 34 may include a first closure link 36 and a
second closure link 38 that are pivotally coupled to the closure
trigger 32 by a pin 35. The second closure link 38 may also be
referred to herein as an "attachment member" and include a
transverse attachment pin 37.
[0122] Still referring to FIG. 4, it can be observed that the first
closure link 36 may have a locking wall or end 39 thereon that is
configured to cooperate with a closure release assembly 60 that is
pivotally coupled to the frame 20. In at least one form, the
closure release assembly 60 may comprise a release button assembly
62 that has a distally protruding locking pawl 64 formed thereon.
The release button assembly 62 may be pivoted in a counterclockwise
direction by a release spring (not shown). As the clinician
depresses the closure trigger 32 from its unactuated position
towards the pistol grip portion 19 of the handle 14, the first
closure link 36 pivots upward to a point wherein the locking pawl
64 drops into retaining engagement with the locking wall 39 on the
first closure link 36 thereby preventing the closure trigger 32
from returning to the unactuated position. See FIG. 18. Thus, the
closure release assembly 60 serves to lock the closure trigger 32
in the fully actuated position. When the clinician desires to
unlock the closure trigger 32 to permit it to be biased to the
unactuated position, the clinician simply pivots the closure
release button assembly 62 such that the locking pawl 64 is moved
out of engagement with the locking wall 39 on the first closure
link 36. When the locking pawl 64 has been moved out of engagement
with the first closure link 36, the closure trigger 32 may pivot
back to the unactuated position. Other closure trigger locking and
release arrangements may also be employed.
[0123] Further to the above, FIGS. 13-15 illustrate the closure
trigger 32 in its unactuated position which is associated with an
open, or unclamped, configuration of the shaft assembly 200 in
which tissue can be positioned between the jaws of the shaft
assembly 200. FIGS. 16-18 illustrate the closure trigger 32 in its
actuated position which is associated with a closed, or clamped,
configuration of the shaft assembly 200 in which tissue is clamped
between the jaws of the shaft assembly 200. Upon comparing FIGS. 14
and 17, the reader will appreciate that, when the closure trigger
32 is moved from its unactuated position (FIG. 14) to its actuated
position (FIG. 17), the closure release button 62 is pivoted
between a first position (FIG. 14) and a second position (FIG. 17).
The rotation of the closure release button 62 can be referred to as
being an upward rotation; however, at least a portion of the
closure release button 62 is being rotated toward the circuit board
100. Referring to FIG. 4, the closure release button 62 can include
an arm 61 extending therefrom and a magnetic element 63, such as a
permanent magnet, for example, mounted to the arm 61. When the
closure release button 62 is rotated from its first position to its
second position, the magnetic element 63 can move toward the
circuit board 100. The circuit board 100 can include at least one
sensor configured to detect the movement of the magnetic element
63. In at least one embodiment, a Hall effect sensor 65, for
example, can be mounted to the bottom surface of the circuit board
100. The Hall effect sensor 65 can be configured to detect changes
in a magnetic field surrounding the Hall effect sensor 65 caused by
the movement of the magnetic element 63. The Hall effect sensor 65
can be in signal communication with a microcontroller 7004 (FIG.
59), for example, which can determine whether the closure release
button 62 is in its first position, which is associated with the
unactuated position of the closure trigger 32 and the open
configuration of the end effector, its second position, which is
associated with the actuated position of the closure trigger 32 and
the closed configuration of the end effector, and/or any position
between the first position and the second position.
[0124] In at least one form, the handle 14 and the frame 20 may
operably support another drive system referred to herein as a
firing drive system 80 that is configured to apply firing motions
to corresponding portions of the interchangeable shaft assembly
attached thereto. The firing drive system may 80 also be referred
to herein as a "second drive system". The firing drive system 80
may employ an electric motor 82, located in the pistol grip portion
19 of the handle 14. In various forms, the motor 82 may be a DC
brushed driving motor having a maximum rotation of, approximately,
25,000 RPM, for example. In other arrangements, the motor may
include a brushless motor, a cordless motor, a synchronous motor, a
stepper motor, or any other suitable electric motor. The motor 82
may be powered by a power source 90 that in one form may comprise a
removable power pack 92. As can be seen in FIG. 4, for example, the
power pack 92 may comprise a proximal housing portion 94 that is
configured for attachment to a distal housing portion 96. The
proximal housing portion 94 and the distal housing portion 96 are
configured to operably support a plurality of batteries 98 therein.
Batteries 98 may each comprise, for example, a Lithium Ion ("LI")
or other suitable battery. The distal housing portion 96 is
configured for removable operable attachment to a control circuit
board assembly 100 which is also operably coupled to the motor 82.
A number of batteries 98 may be connected in series may be used as
the power source for the surgical instrument 10. In addition, the
power source 90 may be replaceable and/or rechargeable.
[0125] As outlined above with respect to other various forms, the
electric motor 82 can include a rotatable shaft (not shown) that
operably interfaces with a gear reducer assembly 84 that is mounted
in meshing engagement with a with a set, or rack, of drive teeth
122 on a longitudinally-movable drive member 120. In use, a voltage
polarity provided by the power source 90 can operate the electric
motor 82 in a clockwise direction wherein the voltage polarity
applied to the electric motor by the battery can be reversed in
order to operate the electric motor 82 in a counter-clockwise
direction. When the electric motor 82 is rotated in one direction,
the drive member 120 will be axially driven in the distal direction
"DD". When the motor 82 is driven in the opposite rotary direction,
the drive member 120 will be axially driven in a proximal direction
"PD". The handle 14 can include a switch which can be configured to
reverse the polarity applied to the electric motor 82 by the power
source 90. As with the other forms described herein, the handle 14
can also include a sensor that is configured to detect the position
of the drive member 120 and/or the direction in which the drive
member 120 is being moved.
[0126] Actuation of the motor 82 can be controlled by a firing
trigger 130 that is pivotally supported on the handle 14. The
firing trigger 130 may be pivoted between an unactuated position
and an actuated position. The firing trigger 130 may be biased into
the unactuated position by a spring 132 or other biasing
arrangement such that when the clinician releases the firing
trigger 130, it may be pivoted or otherwise returned to the
unactuated position by the spring 132 or biasing arrangement. In at
least one form, the firing trigger 130 can be positioned "outboard"
of the closure trigger 32 as was discussed above. In at least one
form, a firing trigger safety button 134 may be pivotally mounted
to the closure trigger 32 by pin 35. The safety button 134 may be
positioned between the firing trigger 130 and the closure trigger
32 and have a pivot arm 136 protruding therefrom. See FIG. 4. When
the closure trigger 32 is in the unactuated position, the safety
button 134 is contained in the handle 14 where the clinician cannot
readily access it and move it between a safety position preventing
actuation of the firing trigger 130 and a firing position wherein
the firing trigger 130 may be fired. As the clinician depresses the
closure trigger 32, the safety button 134 and the firing trigger
130 pivot down wherein they can then be manipulated by the
clinician.
[0127] As discussed above, the handle 14 can include a closure
trigger 32 and a firing trigger 130. Referring to FIGS. 14-18A, the
firing trigger 130 can be pivotably mounted to the closure trigger
32. The closure trigger 32 can include an arm 31 extending
therefrom and the firing trigger 130 can be pivotably mounted to
the arm 31 about a pivot pin 33. When the closure trigger 32 is
moved from its unactuated position (FIG. 14) to its actuated
position (FIG. 17), the firing trigger 130 can descend downwardly,
as outlined above. After the safety button 134 has been moved to
its firing position, referring primarily to FIG. 18A, the firing
trigger 130 can be depressed to operate the motor of the surgical
instrument firing system. In various instances, the handle 14 can
include a tracking system, such as system 800, for example,
configured to determine the position of the closure trigger 32
and/or the position of the firing trigger 130. With primary
reference to FIGS. 14, 17, and 18A, the tracking system 800 can
include a magnetic element, such as permanent magnet 802, for
example, which is mounted to an arm 801 extending from the firing
trigger 130. The tracking system 800 can comprise one or more
sensors, such as a first Hall effect sensor 803 and a second Hall
effect sensor 804, for example, which can be configured to track
the position of the magnet 802. Upon comparing FIGS. 14 and 17, the
reader will appreciate that, when the closure trigger 32 is moved
from its unactuated position to its actuated position, the magnet
802 can move between a first position adjacent the first Hall
effect sensor 803 and a second position adjacent the second Hall
effect sensor 804. Upon comparing FIGS. 17 and 18A, the reader will
further appreciate that, when the firing trigger 130 is moved from
an unfired position (FIG. 17) to a fired position (FIG. 18A), the
magnet 802 can move relative to the second Hall effect sensor 804.
The sensors 803 and 804 can track the movement of the magnet 802
and can be in signal communication with a microcontroller on the
circuit board 100. With data from the first sensor 803 and/or the
second sensor 804, the microcontroller can determine the position
of the magnet 802 along a predefined path and, based on that
position, the microcontroller can determine whether the closure
trigger 32 is in its unactuated position, its actuated position, or
a position therebetween. Similarly, with data from the first sensor
803 and/or the second sensor 804, the microcontroller can determine
the position of the magnet 802 along a predefined path and, based
on that position, the microcontroller can determine whether the
firing trigger 130 is in its unfired position, its fully fired
position, or a position therebetween.
[0128] As indicated above, in at least one form, the longitudinally
movable drive member 120 has a rack of teeth 122 formed thereon for
meshing engagement with a corresponding drive gear 86 of the gear
reducer assembly 84. At least one form also includes a
manually-actuatable "bailout" assembly 140 that is configured to
enable the clinician to manually retract the longitudinally movable
drive member 120 should the motor 82 become disabled. The bailout
assembly 140 may include a lever or bailout handle assembly 142
that is configured to be manually pivoted into ratcheting
engagement with teeth 124 also provided in the drive member 120.
Thus, the clinician can manually retract the drive member 120 by
using the bailout handle assembly 142 to ratchet the drive member
120 in the proximal direction "PD". U.S. Patent Application
Publication No. US 2010/0089970 discloses bailout arrangements and
other components, arrangements and systems that may also be
employed with the various instruments disclosed herein. U.S. patent
application Ser. No. 12/249,117, entitled POWERED SURGICAL CUTTING
AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM, now
U.S. Patent Application Publication No. 2010/0089970, is hereby
incorporated by reference in its entirety.
[0129] Turning now to FIGS. 1 and 7, the interchangeable shaft
assembly 200 includes a surgical end effector 300 that comprises an
elongated channel 302 that is configured to operably support a
staple cartridge 304 therein. The end effector 300 may further
include an anvil 306 that is pivotally supported relative to the
elongated channel 302. The interchangeable shaft assembly 200 may
further include an articulation joint 270 and an articulation lock
350 (FIG. 8) which can be configured to releasably hold the end
effector 300 in a desired position relative to a shaft axis SA-SA.
Details regarding the construction and operation of the end
effector 300, the articulation joint 270 and the articulation lock
350 are set forth in U.S. patent application Ser. No. 13/803,086,
filed Mar. 14, 2013, entitled ARTICULATABLE SURGICAL INSTRUMENT
COMPRISING AN ARTICULATION LOCK. The entire disclosure of U.S.
patent application Ser. No. 13/803,086, filed Mar. 14, 2013,
entitled ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN
ARTICULATION LOCK is hereby incorporated by reference herein. As
can be seen in FIGS. 7 and 8, the interchangeable shaft assembly
200 can further include a proximal housing or nozzle 201 comprised
of nozzle portions 202 and 203. The interchangeable shaft assembly
200 can further include a closure tube 260 which can be utilized to
close and/or open the anvil 306 of the end effector 300. Primarily
referring now to FIGS. 8 and 9, the shaft assembly 200 can include
a spine 210 which can be configured to fixably support a shaft
frame portion 212 of the articulation lock 350. See FIG. 8. The
spine 210 can be configured to, one, slidably support a firing
member 220 therein and, two, slidably support the closure tube 260
which extends around the spine 210. The spine 210 can also be
configured to slidably support a proximal articulation driver 230.
The articulation driver 230 has a distal end 231 that is configured
to operably engage the articulation lock 350. The articulation lock
350 interfaces with an articulation frame 352 that is adapted to
operably engage a drive pin (not shown) on the end effector frame
(not shown). As indicated above, further details regarding the
operation of the articulation lock 350 and the articulation frame
may be found in U.S. patent application Ser. No. 13/803,086. In
various circumstances, the spine 210 can comprise a proximal end
211 which is rotatably supported in a chassis 240. In one
arrangement, for example, the proximal end 211 of the spine 210 has
a thread 214 formed thereon for threaded attachment to a spine
bearing 216 configured to be supported within the chassis 240. See
FIG. 7. Such an arrangement facilitates rotatable attachment of the
spine 210 to the chassis 240 such that the spine 210 may be
selectively rotated about a shaft axis SA-SA relative to the
chassis 240.
[0130] Referring primarily to FIG. 7, the interchangeable shaft
assembly 200 includes a closure shuttle 250 that is slidably
supported within the chassis 240 such that it may be axially moved
relative thereto. As can be seen in FIGS. 3 and 7, the closure
shuttle 250 includes a pair of proximally-protruding hooks 252 that
are configured for attachment to the attachment pin 37 that is
attached to the second closure link 38 as will be discussed in
further detail below. A proximal end 261 of the closure tube 260 is
coupled to the closure shuttle 250 for relative rotation thereto.
For example, a U shaped connector 263 is inserted into an annular
slot 262 in the proximal end 261 of the closure tube 260 and is
retained within vertical slots 253 in the closure shuttle 250. See
FIG. 7. Such an arrangement serves to attach the closure tube 260
to the closure shuttle 250 for axial travel therewith while
enabling the closure tube 260 to rotate relative to the closure
shuttle 250 about the shaft axis SA-SA. A closure spring 268 is
journaled on the closure tube 260 and serves to bias the closure
tube 260 in the proximal direction "PD" which can serve to pivot
the closure trigger into the unactuated position when the shaft
assembly is operably coupled to the handle 14.
[0131] In at least one form, the interchangeable shaft assembly 200
may further include an articulation joint 270. Other
interchangeable shaft assemblies, however, may not be capable of
articulation. As can be seen in FIG. 7, for example, the
articulation joint 270 includes a double pivot closure sleeve
assembly 271. According to various forms, the double pivot closure
sleeve assembly 271 includes an end effector closure sleeve
assembly 272 having upper and lower distally projecting tangs 273,
274. An end effector closure sleeve assembly 272 includes a
horseshoe aperture 275 and a tab 276 for engaging an opening tab on
the anvil 306 in the various manners described in U.S. patent
application Ser. No. 13/803,086, filed Mar. 14, 2013, entitled
ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK
which has been incorporated by reference herein. As described in
further detail therein, the horseshoe aperture 275 and tab 276
engage a tab on the anvil when the anvil 306 is opened. An upper
double pivot link 277 includes upwardly projecting distal and
proximal pivot pins that engage respectively an upper distal pin
hole in the upper proximally projecting tang 273 and an upper
proximal pin hole in an upper distally projecting tang 264 on the
closure tube 260. A lower double pivot link 278 includes upwardly
projecting distal and proximal pivot pins that engage respectively
a lower distal pin hole in the lower proximally projecting tang 274
and a lower proximal pin hole in the lower distally projecting tang
265. See also FIG. 8.
[0132] In use, the closure tube 260 is translated distally
(direction "DD") to close the anvil 306, for example, in response
to the actuation of the closure trigger 32. The anvil 306 is closed
by distally translating the closure tube 260 and thus the shaft
closure sleeve assembly 272, causing it to strike a proximal
surface on the anvil 360 in the manner described in the
aforementioned reference U.S. patent application Ser. No.
13/803,086. As was also described in detail in that reference, the
anvil 306 is opened by proximally translating the closure tube 260
and the shaft closure sleeve assembly 272, causing tab 276 and the
horseshoe aperture 275 to contact and push against the anvil tab to
lift the anvil 306. In the anvil-open position, the shaft closure
tube 260 is moved to its proximal position.
[0133] As indicated above, the surgical instrument 10 may further
include an articulation lock 350 of the types and construction
described in further detail in U.S. patent application Ser. No.
13/803,086 which can be configured and operated to selectively lock
the end effector 300 in position. Such arrangement enables the end
effector 300 to be rotated, or articulated, relative to the shaft
closure tube 260 when the articulation lock 350 is in its unlocked
state. In such an unlocked state, the end effector 300 can be
positioned and pushed against soft tissue and/or bone, for example,
surrounding the surgical site within the patient in order to cause
the end effector 300 to articulate relative to the closure tube
260. The end effector 300 may also be articulated relative to the
closure tube 260 by an articulation driver 230.
[0134] As was also indicated above, the interchangeable shaft
assembly 200 further includes a firing member 220 that is supported
for axial travel within the shaft spine 210. The firing member 220
includes an intermediate firing shaft portion 222 that is
configured for attachment to a distal cutting portion or knife bar
280. The firing member 220 may also be referred to herein as a
"second shaft" and/or a "second shaft assembly". As can be seen in
FIGS. 8 and 9, the intermediate firing shaft portion 222 may
include a longitudinal slot 223 in the distal end thereof which can
be configured to receive a tab 284 on the proximal end 282 of the
distal knife bar 280. The longitudinal slot 223 and the proximal
end 282 can be sized and configured to permit relative movement
therebetween and can comprise a slip joint 286. The slip joint 286
can permit the intermediate firing shaft portion 222 of the firing
drive 220 to be moved to articulate the end effector 300 without
moving, or at least substantially moving, the knife bar 280. Once
the end effector 300 has been suitably oriented, the intermediate
firing shaft portion 222 can be advanced distally until a proximal
sidewall of the longitudinal slot 223 comes into contact with the
tab 284 in order to advance the knife bar 280 and fire the staple
cartridge positioned within the channel 302 As can be further seen
in FIGS. 8 and 9, the shaft spine 210 has an elongate opening or
window 213 therein to facilitate assembly and insertion of the
intermediate firing shaft portion 222 into the shaft frame 210.
Once the intermediate firing shaft portion 222 has been inserted
therein, a top frame segment 215 may be engaged with the shaft
frame 212 to enclose the intermediate firing shaft portion 222 and
knife bar 280 therein. Further description of the operation of the
firing member 220 may be found in U.S. patent application Ser. No.
13/803,086.
[0135] Further to the above, the shaft assembly 200 can include a
clutch assembly 400 which can be configured to selectively and
releasably couple the articulation driver 230 to the firing member
220. In one form, the clutch assembly 400 includes a lock collar,
or sleeve 402, positioned around the firing member 220 wherein the
lock sleeve 402 can be rotated between an engaged position in which
the lock sleeve 402 couples the articulation driver 360 to the
firing member 220 and a disengaged position in which the
articulation driver 360 is not operably coupled to the firing
member 200. When lock sleeve 402 is in its engaged position, distal
movement of the firing member 220 can move the articulation driver
360 distally and, correspondingly, proximal movement of the firing
member 220 can move the articulation driver 230 proximally. When
lock sleeve 402 is in its disengaged position, movement of the
firing member 220 is not transmitted to the articulation driver 230
and, as a result, the firing member 220 can move independently of
the articulation driver 230. In various circumstances, the
articulation driver 230 can be held in position by the articulation
lock 350 when the articulation driver 230 is not being moved in the
proximal or distal directions by the firing member 220.
[0136] Referring primarily to FIG. 9, the lock sleeve 402 can
comprise a cylindrical, or an at least substantially cylindrical,
body including a longitudinal aperture 403 defined therein
configured to receive the firing member 220. The lock sleeve 402
can comprise diametrically-opposed, inwardly-facing lock
protrusions 404 and an outwardly-facing lock member 406. The lock
protrusions 404 can be configured to be selectively engaged with
the firing member 220. More particularly, when the lock sleeve 402
is in its engaged position, the lock protrusions 404 are positioned
within a drive notch 224 defined in the firing member 220 such that
a distal pushing force and/or a proximal pulling force can be
transmitted from the firing member 220 to the lock sleeve 402. When
the lock sleeve 402 is in its engaged position, the second lock
member 406 is received within a drive notch 232 defined in the
articulation driver 230 such that the distal pushing force and/or
the proximal pulling force applied to the lock sleeve 402 can be
transmitted to the articulation driver 230. In effect, the firing
member 220, the lock sleeve 402, and the articulation driver 230
will move together when the lock sleeve 402 is in its engaged
position. On the other hand, when the lock sleeve 402 is in its
disengaged position, the lock protrusions 404 may not be positioned
within the drive notch 224 of the firing member 220 and, as a
result, a distal pushing force and/or a proximal pulling force may
not be transmitted from the firing member 220 to the lock sleeve
402. Correspondingly, the distal pushing force and/or the proximal
pulling force may not be transmitted to the articulation driver
230. In such circumstances, the firing member 220 can be slid
proximally and/or distally relative to the lock sleeve 402 and the
proximal articulation driver 230.
[0137] As can be seen in FIGS. 8-12, the shaft assembly 200 further
includes a switch drum 500 that is rotatably received on the
closure tube 260. The switch drum 500 comprises a hollow shaft
segment 502 that has a shaft boss 504 formed thereon for receive an
outwardly protruding actuation pin 410 therein. In various
circumstances, the actuation pin 410 extends through a slot 267
into a longitudinal slot 408 provided in the lock sleeve 402 to
facilitate axial movement of the lock sleeve 402 when it is engaged
with the articulation driver 230. A rotary torsion spring 420 is
configured to engage the boss 504 on the switch drum 500 and a
portion of the nozzle housing 203 as shown in FIG. 10 to apply a
biasing force to the switch drum 500. The switch drum 500 can
further comprise at least partially circumferential openings 506
defined therein which, referring to FIGS. 5 and 6, can be
configured to receive circumferential mounts 204, 205 extending
from the nozzle halves 202, 203 and permit relative rotation, but
not translation, between the switch drum 500 and the proximal
nozzle 201. As can be seen in those Figures, the mounts 204 and 205
also extend through openings 266 in the closure tube 260 to be
seated in recesses 211 in the shaft spine 210. However, rotation of
the nozzle 201 to a point where the mounts 204, 205 reach the end
of their respective slots 506 in the switch drum 500 will result in
rotation of the switch drum 500 about the shaft axis SA-SA.
Rotation of the switch drum 500 will ultimately result in the
rotation of eth actuation pin 410 and the lock sleeve 402 between
its engaged and disengaged positions. Thus, in essence, the nozzle
201 may be employed to operably engage and disengage the
articulation drive system with the firing drive system in the
various manners described in further detail in U.S. patent
application Ser. No. 13/803,086.
[0138] As also illustrated in FIGS. 8-12, the shaft assembly 200
can comprise a slip ring assembly 600 which can be configured to
conduct electrical power to and/or from the end effector 300 and/or
communicate signals to and/or from the end effector 300, for
example. The slip ring assembly 600 can comprise a proximal
connector flange 604 mounted to a chassis flange 242 extending from
the chassis 240 and a distal connector flange 601 positioned within
a slot defined in the shaft housings 202, 203. The proximal
connector flange 604 can comprise a first face and the distal
connector flange 601 can comprise a second face which is positioned
adjacent to and movable relative to the first face. The distal
connector flange 601 can rotate relative to the proximal connector
flange 604 about the shaft axis SA-SA. The proximal connector
flange 604 can comprise a plurality of concentric, or at least
substantially concentric, conductors 602 defined in the first face
thereof. A connector 607 can be mounted on the proximal side of the
connector flange 601 and may have a plurality of contacts (not
shown) wherein each contact corresponds to and is in electrical
contact with one of the conductors 602. Such an arrangement permits
relative rotation between the proximal connector flange 604 and the
distal connector flange 601 while maintaining electrical contact
therebetween. The proximal connector flange 604 can include an
electrical connector 606 which can place the conductors 602 in
signal communication with a shaft circuit board 610 mounted to the
shaft chassis 240, for example. In at least one instance, a wiring
harness comprising a plurality of conductors can extend between the
electrical connector 606 and the shaft circuit board 610. The
electrical connector 606 may extend proximally through a connector
opening 243 defined in the chassis mounting flange 242. See FIG. 7.
U.S. patent application Ser. No. 13/800,067, entitled STAPLE
CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013,
is incorporated by reference in its entirety. U.S. patent
application Ser. No. 13/800,025, entitled STAPLE CARTRIDGE TISSUE
THICKNESS SENSOR SYSTEM, filed on Mar. 13, 2013, is incorporated by
reference in its entirety. Further details regarding slip ring
assembly 600 may be found in U.S. patent application Ser. No.
13/803,086.
[0139] As discussed above, the shaft assembly 200 can include a
proximal portion which is fixably mounted to the handle 14 and a
distal portion which is rotatable about a longitudinal axis. The
rotatable distal shaft portion can be rotated relative to the
proximal portion about the slip ring assembly 600, as discussed
above. The distal connector flange 601 of the slip ring assembly
600 can be positioned within the rotatable distal shaft portion.
Moreover, further to the above, the switch drum 500 can also be
positioned within the rotatable distal shaft portion. When the
rotatable distal shaft portion is rotated, the distal connector
flange 601 and the switch drum 500 can be rotated synchronously
with one another. In addition, the switch drum 500 can be rotated
between a first position and a second position relative to the
distal connector flange 601. When the switch drum 500 is in its
first position, the articulation drive system may be operably
disengaged from the firing drive system and, thus, the operation of
the firing drive system may not articulate the end effector 300 of
the shaft assembly 200. When the switch drum 500 is in its second
position, the articulation drive system may be operably engaged
with the firing drive system and, thus, the operation of the firing
drive system may articulate the end effector 300 of the shaft
assembly 200. When the switch drum 500 is moved between its first
position and its second position, the switch drum 500 is moved
relative to distal connector flange 601. In various instances, the
shaft assembly 200 can comprise at least one sensor configured to
detect the position of the switch drum 500. Turning now to FIGS. 11
and 12, the distal connector flange 601 can comprise a Hall effect
sensor 605, for example, and the switch drum 500 can comprise a
magnetic element, such as permanent magnet 505, for example. The
Hall effect sensor 605 can be configured to detect the position of
the permanent magnet 505. When the switch drum 500 is rotated
between its first position and its second position, the permanent
magnet 505 can move relative to the Hall effect sensor 605. In
various instances, Hall effect sensor 605 can detect changes in a
magnetic field created when the permanent magnet 505 is moved. The
Hall effect sensor 605 can be in signal communication with the
shaft circuit board 610 and/or the handle circuit board 100, for
example. Based on the signal from the Hall effect sensor 605, a
microcontroller on the shaft circuit board 610 and/or the handle
circuit board 100 can determine whether the articulation drive
system is engaged with or disengaged from the firing drive
system.
[0140] Referring again to FIGS. 3 and 7, the chassis 240 includes
at least one, and preferably two, tapered attachment portions 244
formed thereon that are adapted to be received within corresponding
dovetail slots 702 formed within a distal attachment flange portion
700 of the frame 20. Each dovetail slot 702 may be tapered or,
stated another way, be somewhat V-shaped to seatingly receive the
attachment portions 244 therein. As can be further seen in FIGS. 3
and 7, a shaft attachment lug 226 is formed on the proximal end of
the intermediate firing shaft 222. As will be discussed in further
detail below, when the interchangeable shaft assembly 200 is
coupled to the handle 14, the shaft attachment lug 226 is received
in a firing shaft attachment cradle 126 formed in the distal end
125 of the longitudinal drive member 120. See FIGS. 3 and 6.
[0141] Various shaft assembly embodiments employ a latch system 710
for removably coupling the shaft assembly 200 to the housing 12 and
more specifically to the frame 20. As can be seen in FIG. 7, for
example, in at least one form, the latch system 710 includes a lock
member or lock yoke 712 that is movably coupled to the chassis 240.
In the illustrated embodiment, for example, the lock yoke 712 has a
U-shape with two spaced downwardly extending legs 714. The legs 714
each have a pivot lug 716 formed thereon that are adapted to be
received in corresponding holes 245 formed in the chassis 240. Such
arrangement facilitates pivotal attachment of the lock yoke 712 to
the chassis 240. The lock yoke 712 may include two proximally
protruding lock lugs 714 that are configured for releasable
engagement with corresponding lock detents or grooves 704 in the
distal attachment flange 700 of the frame 20. See FIG. 3. In
various forms, the lock yoke 712 is biased in the proximal
direction by spring or biasing member (not shown). Actuation of the
lock yoke 712 may be accomplished by a latch button 722 that is
slidably mounted on a latch actuator assembly 720 that is mounted
to the chassis 240. The latch button 722 may be biased in a
proximal direction relative to the lock yoke 712. As will be
discussed in further detail below, the lock yoke 712 may be moved
to an unlocked position by biasing the latch button the in distal
direction which also causes the lock yoke 712 to pivot out of
retaining engagement with the distal attachment flange 700 of the
frame 20. When the lock yoke 712 is in "retaining engagement" with
the distal attachment flange 700 of the frame 20, the lock lugs 716
are retainingly seated within the corresponding lock detents or
grooves 704 in the distal attachment flange 700.
[0142] When employing an interchangeable shaft assembly that
includes an end effector of the type described herein that is
adapted to cut and fasten tissue, as well as other types of end
effectors, it may be desirable to prevent inadvertent detachment of
the interchangeable shaft assembly from the housing during
actuation of the end effector. For example, in use the clinician
may actuate the closure trigger 32 to grasp and manipulate the
target tissue into a desired position. Once the target tissue is
positioned within the end effector 300 in a desired orientation,
the clinician may then fully actuate the closure trigger 32 to
close the anvil 306 and clamp the target tissue in position for
cutting and stapling. In that instance, the first drive system 30
has been fully actuated. After the target tissue has been clamped
in the end effector 300, it may be desirable to prevent the
inadvertent detachment of the shaft assembly 200 from the housing
12. One form of the latch system 710 is configured to prevent such
inadvertent detachment.
[0143] As can be most particularly seen in FIG. 7, the lock yoke
712 includes at least one and preferably two lock hooks 718 that
are adapted to contact corresponding lock lug portions 256 that are
formed on the closure shuttle 250. Referring to FIGS. 13-15, when
the closure shuttle 250 is in an unactuated position (i.e., the
first drive system 30 is unactuated and the anvil 306 is open), the
lock yoke 712 may be pivoted in a distal direction to unlock the
interchangeable shaft assembly 200 from the housing 12. When in
that position, the lock hooks 718 do not contact the lock lug
portions 256 on the closure shuttle 250. However, when the closure
shuttle 250 is moved to an actuated position (i.e., the first drive
system 30 is actuated and the anvil 306 is in the closed position),
the lock yoke 712 is prevented from being pivoted to an unlocked
position. See FIGS. 16-18. Stated another way, if the clinician
were to attempt to pivot the lock yoke 712 to an unlocked position
or, for example, the lock yoke 712 was in advertently bumped or
contacted in a manner that might otherwise cause it to pivot
distally, the lock hooks 718 on the lock yoke 712 will contact the
lock lugs 256 on the closure shuttle 250 and prevent movement of
the lock yoke 712 to an unlocked position.
[0144] Attachment of the interchangeable shaft assembly 200 to the
handle 14 will now be described with reference to FIG. 3. To
commence the coupling process, the clinician may position the
chassis 240 of the interchangeable shaft assembly 200 above or
adjacent to the distal attachment flange 700 of the frame 20 such
that the tapered attachment portions 244 formed on the chassis 240
are aligned with the dovetail slots 702 in the frame 20. The
clinician may then move the shaft assembly 200 along an
installation axis IA that is perpendicular to the shaft axis SA-SA
to seat the attachment portions 244 in "operable engagement" with
the corresponding dovetail receiving slots 702. In doing so, the
shaft attachment lug 226 on the intermediate firing shaft 222 will
also be seated in the cradle 126 in the longitudinally movable
drive member 120 and the portions of pin 37 on the second closure
link 38 will be seated in the corresponding hooks 252 in the
closure yoke 250. As used herein, the term "operable engagement" in
the context of two components means that the two components are
sufficiently engaged with each other so that upon application of an
actuation motion thereto, the components may carry out their
intended action, function and/or procedure.
[0145] As discussed above, at least five systems of the
interchangeable shaft assembly 200 can be operably coupled with at
least five corresponding systems of the handle 14. A first system
can comprise a frame system which couples and/or aligns the frame
or spine of the shaft assembly 200 with the frame 20 of the handle
14. Another system can comprise a closure drive system 30 which can
operably connect the closure trigger 32 of the handle 14 and the
closure tube 260 and the anvil 306 of the shaft assembly 200. As
outlined above, the closure tube attachment yoke 250 of the shaft
assembly 200 can be engaged with the pin 37 on the second closure
link 38. Another system can comprise the firing drive system 80
which can operably connect the firing trigger 130 of the handle 14
with the intermediate firing shaft 222 of the shaft assembly 200.
As outlined above, the shaft attachment lug 226 can be operably
connected with the cradle 126 of the longitudinal drive member 120.
Another system can comprise an electrical system which can signal
to a controller in the handle 14, such as microcontroller, for
example, that a shaft assembly, such as shaft assembly 200, for
example, has been operably engaged with the handle 14 and/or, two,
conduct power and/or communication signals between the shaft
assembly 200 and the handle 14. For instance, the shaft assembly
200 can include an electrical connector 4010 that is operably
mounted to the shaft circuit board 610. The electrical connector
4010 is configured for mating engagement with a corresponding
electrical connector 4000 on the handle control board 100. Further
details regaining the circuitry and control systems may be found in
U.S. patent application Ser. No. 13/803,086, the entire disclosure
of which was previously incorporated by reference herein. The fifth
system may consist of the latching system for releasably locking
the shaft assembly 200 to the handle 14.
[0146] Referring again to FIGS. 2 and 3, the handle 14 can include
an electrical connector 4000 comprising a plurality of electrical
contacts. Turning now to FIG. 59, the electrical connector 4000 can
comprise a first contact 4001a, a second contact 4001b, a third
contact 4001c, a fourth contact 4001d, a fifth contact 4001e, and a
sixth contact 4001f, for example. While the illustrated embodiment
utilizes six contacts, other embodiments are envisioned which may
utilize more than six contacts or less than six contacts. As
illustrated in FIG. 59, the first contact 4001a can be in
electrical communication with a transistor 4008, contacts
4001b-4001e can be in electrical communication with a
microcontroller 7004, and the sixth contact 4001f can be in
electrical communication with a ground. In certain circumstances,
one or more of the electrical contacts 4001b-4001e may be in
electrical communication with one or more output channels of the
microcontroller 7004 and can be energized, or have a voltage
potential applied thereto, when the handle 1042 is in a powered
state. In some circumstances, one or more of the electrical
contacts 4001b-4001e may be in electrical communication with one or
more input channels of the microcontroller 7004 and, when the
handle 14 is in a powered state, the microcontroller 7004 can be
configured to detect when a voltage potential is applied to such
electrical contacts. When a shaft assembly, such as shaft assembly
200, for example, is assembled to the handle 14, the electrical
contacts 4001a-4001f may not communicate with each other. When a
shaft assembly is not assembled to the handle 14, however, the
electrical contacts 4001a-4001f of the electrical connector 4000
may be exposed and, in some circumstances, one or more of the
contacts 4001a-4001f may be accidentally placed in electrical
communication with each other. Such circumstances can arise when
one or more of the contacts 4001a-4001f come into contact with an
electrically conductive material, for example. When this occurs,
the microcontroller 7004 can receive an erroneous input and/or the
shaft assembly 200 can receive an erroneous output, for example. To
address this issue, in various circumstances, the handle 14 may be
unpowered when a shaft assembly, such as shaft assembly 200, for
example, is not attached to the handle 14. In other circumstances,
the handle 1042 can be powered when a shaft assembly, such as shaft
assembly 200, for example, is not attached thereto. In such
circumstances, the microcontroller 7004 can be configured to ignore
inputs, or voltage potentials, applied to the contacts in
electrical communication with the microcontroller 7004, i.e.,
contacts 4001b-4001e, for example, until a shaft assembly is
attached to the handle 14. Eventhough the microcontroller 7004 may
be supplied with power to operate other functionalities of the
handle 14 in such circumstances, the handle 14 may be in a
powered-down state. In a way, the electrical connector 4000 may be
in a powered-down state as voltage potentials applied to the
electrical contacts 4001b-4001e may not affect the operation of the
handle 14. The reader will appreciate that, eventhough contacts
4001b-4001e may be in a powered-down state, the electrical contacts
4001a and 4001f, which are not in electrical communication with the
microcontroller 7004, may or may not be in a powered-down state.
For instance, sixth contact 4001f may remain in electrical
communication with a ground regardless of whether the handle 14 is
in a powered-up or a powered-down state. Furthermore, the
transistor 4008, and/or any other suitable arrangement of
transistors, such as transistor 4010, for example, and/or switches
may be configured to control the supply of power from a power
source 4004, such as a battery 90 within the handle 14, for
example, to the first electrical contact 4001a regardless of
whether the handle 14 is in a powered-up or a powered-down state.
In various circumstances, the shaft assembly 200, for example, can
be configured to change the state of the transistor 4008 when the
shaft assembly 200 is engaged with the handle 14. In certain
circumstances, further to the below, a Hall effect sensor 4002 can
be configured to switch the state of transistor 4010 which, as a
result, can switch the state of transistor 4008 and ultimately
supply power from power source 4004 to first contact 4001 a. In
this way, both the power circuits and the signal circuits to the
connector 4000 can be powered down when a shaft assembly is not
installed to the handle 14 and powered up when a shaft assembly is
installed to the handle 14.
[0147] In various circumstances, referring again to FIG. 59, the
handle 14 can include the Hall effect sensor 4002, for example,
which can be configured to detect a detectable element, such as a
magnetic element 4007 (FIG. 3), for example, on a shaft assembly,
such as shaft assembly 200, for example, when the shaft assembly is
coupled to the handle 14. The Hall effect sensor 4002 can be
powered by a power source 4006, such as a battery, for example,
which can, in effect, amplify the detection signal of the Hall
effect sensor 4002 and communicate with an input channel of the
microcontroller 7004 via the circuit illustrated in FIG. 59. Once
the microcontroller 7004 has a received an input indicating that a
shaft assembly has been at least partially coupled to the handle
14, and that, as a result, the electrical contacts 4001a-4001f are
no longer exposed, the microcontroller 7004 can enter into its
normal, or powered-up, operating state. In such an operating state,
the microcontroller 7004 will evaluate the signals transmitted to
one or more of the contacts 4001b-4001e from the shaft assembly
and/or transmit signals to the shaft assembly through one or more
of the contacts 4001b-4001e in normal use thereof. In various
circumstances, the shaft assembly 1200 may have to be fully seated
before the Hall effect sensor 4002 can detect the magnetic element
4007. While a Hall effect sensor 4002 can be utilized to detect the
presence of the shaft assembly 200, any suitable system of sensors
and/or switches can be utilized to detect whether a shaft assembly
has been assembled to the handle 14, for example. In this way,
further to the above, both the power circuits and the signal
circuits to the connector 4000 can be powered down when a shaft
assembly is not installed to the handle 14 and powered up when a
shaft assembly is installed to the handle 14.
[0148] In various embodiments, any number of magnetic sensing
elements may be employed to detect whether a shaft assembly has
been assembled to the handle 14, for example. For example, the
technologies used for magnetic field sensing include search coil,
fluxgate, optically pumped, nuclear precession, SQUID, Hall-effect,
anisotropic magnetoresistance, giant magnetoresistance, magnetic
tunnel junctions, giant magnetoimpedance,
magnetostrictive/piezoelectric composites, magnetodiode,
magnetotransistor, fiber optic, magnetooptic, and
microelectromechanical systems-based magnetic sensors, among
others.
[0149] Referring to FIG. 59, the microcontroller 7004 may generally
comprise a microprocessor ("processor") and one or more memory
units operationally coupled to the processor. By executing
instruction code stored in the memory, the processor may control
various components of the surgical instrument, such as the motor,
various drive systems, and/or a user display, for example. The
microcontroller 7004 may be implemented using integrated and/or
discrete hardware elements, software elements, and/or a combination
of both. Examples of integrated hardware elements may include
processors, microprocessors, microcontrollers, integrated circuits,
application specific integrated circuits (ASIC), programmable logic
devices (PLD), digital signal processors (DSP), field programmable
gate arrays (FPGA), logic gates, registers, semiconductor devices,
chips, microchips, chip sets, microcontrollers, system-on-chip
(SoC), and/or system-in-package (SIP). Examples of discrete
hardware elements may include circuits and/or circuit elements such
as logic gates, field effect transistors, bipolar transistors,
resistors, capacitors, inductors, and/or relays. In certain
instances, the microcontroller 7004 may include a hybrid circuit
comprising discrete and integrated circuit elements or components
on one or more substrates, for example.
[0150] Referring to FIG. 59, the microcontroller 7004 may be an LM
4F230H5QR, available from Texas Instruments, for example. In
certain instances, the Texas Instruments LM4F230H5QR is an ARM
Cortex-M4F Processor Core comprising on-chip memory of 256 KB
single-cycle flash memory, or other non-volatile memory, up to 40
MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB
single-cycle serial random access memory (SRAM), internal read-only
memory (ROM) loaded with StellarisWare.RTM. software, 2 KB
electrically erasable programmable read-only memory (EEPROM), one
or more pulse width modulation (PWM) modules, one or more
quadrature encoder inputs (QED analog, one or more 12-bit
Analog-to-Digital Converters (ADC) with 12 analog input channels,
among other features that are readily available. Other
microcontrollers may be readily substituted for use with the
present disclosure. Accordingly, the present disclosure should not
be limited in this context.
[0151] As discussed above, the handle 14 and/or the shaft assembly
200 can include systems and configurations configured to prevent,
or at least reduce the possibility of, the contacts of the handle
electrical connector 4000 and/or the contacts of the shaft
electrical connector 4010 from becoming shorted out when the shaft
assembly 200 is not assembled, or completely assembled, to the
handle 14. Referring to FIG. 3, the handle electrical connector
4000 can be at least partially recessed within a cavity 4009
defined in the handle frame 20. The six contacts 4001a-4001f of the
electrical connector 4000 can be completely recessed within the
cavity 4009. Such arrangements can reduce the possibility of an
object accidentally contacting one or more of the contacts
4001a-4001f. Similarly, the shaft electrical connector 4010 can be
positioned within a recess defined in the shaft chassis 240 which
can reduce the possibility of an object accidentally contacting one
or more of the contacts 4011a-4011f of the shaft electrical
connector 4010. With regard to the particular embodiment depicted
in FIG. 3, the shaft contacts 4011a-4011f can comprise male
contacts. In at least one embodiment, each shaft contact
4011a-4011f can comprise a flexible projection extending therefrom
which can be configured to engage a corresponding handle contact
4001a-4001f, for example. The handle contacts 4001a-4001f can
comprise female contacts. In at least one embodiment, each handle
contact 4001a-4001f can comprise a flat surface, for example,
against which the male shaft contacts 4001a-4001f can wipe, or
slide, against and maintain an electrically conductive interface
therebetween. In various instances, the direction in which the
shaft assembly 200 is assembled to the handle 14 can be parallel
to, or at least substantially parallel to, the handle contacts
4001a-4001f such that the shaft contacts 4011a-4011f slide against
the handle contacts 4001a-4001f when the shaft assembly 200 is
assembled to the handle 14. In various alternative embodiments, the
handle contacts 4001a-4001f can comprise male contacts and the
shaft contacts 4011a-4011f can comprise female contacts. In certain
alternative embodiments, the handle contacts 4001a-4001f and the
shaft contacts 4011a-4011f can comprise any suitable arrangement of
contacts.
[0152] In various instances, the handle 14 can comprise a connector
guard configured to at least partially cover the handle electrical
connector 4000 and/or a connector guard configured to at least
partially cover the shaft electrical connector 4010. A connector
guard can prevent, or at least reduce the possibility of, an object
accidentally touching the contacts of an electrical connector when
the shaft assembly is not assembled to, or only partially assembled
to, the handle. A connector guard can be movable. For instance, the
connector guard can be moved between a guarded position in which it
at least partially guards a connector and an unguarded position in
which it does not guard, or at least guards less of, the connector.
In at least one embodiment, a connector guard can be displaced as
the shaft assembly is being assembled to the handle. For instance,
if the handle comprises a handle connector guard, the shaft
assembly can contact and displace the handle connector guard as the
shaft assembly is being assembled to the handle. Similarly, if the
shaft assembly comprises a shaft connector guard, the handle can
contact and displace the shaft connector guard as the shaft
assembly is being assembled to the handle. In various instances, a
connector guard can comprise a door, for example. In at least one
instance, the door can comprise a beveled surface which, when
contacted by the handle or shaft, can facilitate the displacement
of the door in a certain direction. In various instances, the
connector guard can be translated and/or rotated, for example. In
certain instances, a connector guard can comprise at least one film
which covers the contacts of an electrical connector. When the
shaft assembly is assembled to the handle, the film can become
ruptured. In at least one instance, the male contacts of a
connector can penetrate the film before engaging the corresponding
contacts positioned underneath the film.
[0153] As described above, the surgical instrument can include a
system which can selectively power-up, or activate, the contacts of
an electrical connector, such as the electrical connector 4000, for
example. In various instances, the contacts can be transitioned
between an unactivated condition and an activated condition. In
certain instances, the contacts can be transitioned between a
monitored condition, a deactivated condition, and an activated
condition. For instance, the microcontroller 7004, for example, can
monitor the contacts 4001a-4001f when a shaft assembly has not been
assembled to the handle 14 to determine whether one or more of the
contacts 4001a-4001f may have been shorted. The microcontroller
7004 can be configured to apply a low voltage potential to each of
the contacts 4001a-4001f and assess whether only a minimal
resistance is present at each of the contacts. Such an operating
state can comprise the monitored condition. In the event that the
resistance detected at a contact is high, or above a threshold
resistance, the microcontroller 7004 can deactivate that contact,
more than one contact, or, alternatively, all of the contacts. Such
an operating state can comprise the deactivated condition. If a
shaft assembly is assembled to the handle 14 and it is detected by
the microcontroller 7004, as discussed above, the microcontroller
7004 can increase the voltage potential to the contacts
4001a-4001f. Such an operating state can comprise the activated
condition.
[0154] The various shaft assemblies disclosed herein may employ
sensors and various other components that require electrical
communication with the controller in the housing. These shaft
assemblies generally are configured to be able to rotate relative
to the housing necessitating a connection that facilitates such
electrical communication between two or more components that may
rotate relative to each other. When employing end effectors of the
types disclosed herein, the connector arrangements must be
relatively robust in nature while also being somewhat compact to
fit into the shaft assembly connector portion.
[0155] FIGS. 19-22 depict one form of electric coupler or slip ring
connector 1600 that may be employed with, for example an
interchangeable shaft assembly 1200 or a variety of other
applications that require electrical connections between components
that rotate relative to each other. The shaft assembly 1200 may be
similar to shaft assembly 200 described herein and include a
closure tube or outer shaft 1260 and a proximal nozzle 1201 (the
upper half of nozzle 1201 is omitted for clarity). In the
illustrated example, the outer shaft 1260 is mounted on a shaft
spine 1210 such that the outer tube 1260 may be selectively axially
movable thereon. The proximal ends of the shaft spine 1210 and the
outer tube 1260 may be rotatably coupled to a chassis 1240 for
rotation relative thereto about a shaft axis SA-SA. As was
discussed above, the proximal nozzle 1201 may include mounts or
mounting lugs 1204 (FIG. 20) that protrude inwardly from the nozzle
portions and extend through corresponding openings 1266 in the
outer tube 1260 to be seated in corresponding recesses 1211 in the
shaft spine 1210. Thus, to rotate the outer shaft 1260 and spine
shaft 1210 and presumably an end effector (not shown) coupled
thereto about the shaft axis SA-SA relative to the chassis 1240,
the clinician simply rotates the nozzle 1201 as represented by
arrows "R" in FIG. 19.
[0156] When sensors are employed at the end effector or at
locations within or on the shaft assembly for example, conductors
such as wires and/or traces (not shown) may be received or mounted
within the outer tube 1260 or could even be routed along the outer
tube 1260 from the sensors to a distal electrical component 1800
mounted within the nozzle 1201. Thus, the distal electrical
component 1800 is rotatable with the nozzle 1201 about the shaft
axis SA-SA. In the embodiment illustrated in FIG. 20, the
electrical component 1800 comprises a connector, battery, etc. that
includes contacts 1802, 1804, 1806, and 1808 that are laterally
displaced from each other.
[0157] The slip ring connector 1600 further includes a mounting
member 1610 that includes a cylindrical body portion 1612 that
defines an annular mounting surface 1613. A distal flange 1614 may
be formed on at least one end of the cylindrical body portion 1612.
The body portion 1612 of the mounting member 1610 is sized to be
non-rotatably mounted on a mounting hub 1241 on the chassis 1240.
In the illustrated embodiment, one distal flange 1614 is provided
on one end of the body portion 1612. A second flange 1243 is formed
on the chassis 1240 such that when the body portion 1612 is fixedly
(non-rotatably) mounted thereon, the second flange 1243 abuts the
proximal end of the body portion 1612.
[0158] The slip ring connector 1600 also employs a unique and novel
annular circuit trace assembly 1620 that is wrapped around the
annular mounting surface 1613 of the body portion 1612 such that it
is received between the first and second flanges 1614 and 1243.
Referring now to FIGS. 21 and 22, the circuit trace assembly 1620
may comprise an adhesive-backed flexible substrate 1622 that may be
wrapped around the circumference of the body portion 1612 (i.e.,
the annular mounting surface 1613). Prior to being wrapped around
the body portion 1612, the flexible substrate 1622 may have a
"T-shape" with a first annular portion 1624 and a lead portion
1626. As can also be seen in FIGS. 19-21, the circuit trace
assembly 1620 may further include circuit traces 1630, 1640, 1650,
1660 that may comprise, for example, electrically-conductive
gold-plated traces. However, other electrically-conductive
materials may also be used. Each electrically-conductive circuit
trace includes an "annular portion" that will form an annular part
of the trace when the substrate is wrapped around the body portion
1612 as well as another "lead portion" that extends transversely
from or perpendicular from the annular portion. More specifically,
referring to FIG. 22, first electrically-conductive circuit trace
1630 has a first annular portion 1632 and first lead portion 1634.
The second electrically-conductive circuit trace 1640 has a second
annular portion 1642 and a second lead portion 1644 extending
transversely or perpendicularly therefrom. The third electrically
conductive circuit trace 1650 has a third annular portion 1652 and
a third lead portion 1654 extending transversely or perpendicularly
therefrom. The fourth electrically-conductive circuit trace has a
fourth annular portion 1662 and a fourth lead portion 1664
extending transversely or perpendicularly therefrom. The
electrically-conductive circuit traces 1630, 1640, 1650, 1660 may
be applied to the flexible substrate 1622 while the substrate is in
a planar orientation (i.e., prior to being wrapped onto the annular
body portion 1612 of the mounting member 1610) using conventional
manufacturing techniques. As can be seen in FIG. 22, the annular
portions 1632, 1642, 1652, 1662 are laterally displaced from each
other. Likewise, the lead portions 1634, 1644, 1654, 1664 are
laterally displaced from each other.
[0159] When the circuit trace assembly 1620 is wrapped around the
annular mounting surface 1613 and attached thereto by adhesive,
double-stick tape, etc., the ends of the portion of the substrate
that contains the annular portions 1632, 1642, 1652, 1664 are
butted together such that the annular portions 1632, 1642, 1652,
1664 form discrete continuous annular electrically-conductive paths
1636, 1646, 1656, 1666, respectively that extend around the shaft
axis SA-SA. Thus, the electrically-conductive paths 1636, 1646,
1656, and 1666 are laterally or axially displaced from each other
along the shaft axis SA-SA. The lead portion 1626 may extend
through a slot 1245 in the flange 1243 and be electrically coupled
to a circuit board (see e.g., FIG. 7--circuit board 610) or other
suitable electrical component(s).
[0160] In the depicted embodiment for example, the electrical
component 1800 is mounted within the nozzle 1261 for rotation about
the mounting member 1610 such that: contact 1802 is in constant
electrical contact with the first annular electrically-conductive
path 1636; contact 1804 is in constant electrical contact with the
second annular electrically-conductive path 1646; contact 1806 is
in constant electrical contact with the third annular
electrically-conductive path 1656; and contact 1808 is in constant
electrical contact with the fourth electrically-conductive path
1666. It will be understood however, that the various advantages of
the slip ring connector 1600 may also be obtained in applications
wherein the mounting member 1610 is supported for rotation about
the shaft axis SA-SA and the electrical component 1800 is fixedly
mounted relative thereto. It will be further appreciated that the
slip ring connector 1600 may be effectively employed in connection
with a variety of different components and applications outside the
field of surgery wherein it is desirable to provide electrical
connections between components that rotate relative to each
other.
[0161] The slip ring connector 1600 comprises a radial slip ring
that provides a conductive contact means of passing signal(s) and
power to and from any radial position and after shaft rotation. In
applications wherein the electrical component comprises a battery
contact, the battery contact position can be situated relative to
the mounting member to minimize any tolerance stack up between
those components. The coupler arrangement may represent a low cost
coupling arrangement that can be assembled with minimal
manufacturing costs. The gold plated traces may also minimize the
likelihood of corrosion. The unique and novel contact arrangement
facilitates complete clockwise and counterclockwise rotation about
the shaft axis SA-SA while remaining in electrical contact with the
corresponding annular electrically-conductive paths.
[0162] FIGS. 23-25 depict one form of electric coupler or slip ring
connector 1600' that may be employed with, for example an
interchangeable shaft assembly 1200' or a variety of other
applications that require electrical connections between components
that rotate relative to each other. The shaft assembly 1200' may be
similar to shaft assembly 1200 described herein and include a
closure tube or outer shaft 1260 and a proximal nozzle 1201 (the
upper half of nozzle 1201 is omitted for clarity). In the
illustrated example, the outer shaft 1260 is mounted on a shaft
spine 1210 such that the outer tube 1260 may be selectively axially
movable thereon. The proximal ends of the shaft spine 1210 and the
outer tube 1260 may be rotatably coupled to a chassis 1240' for
rotation relative thereto about a shaft axis SA-SA. As was
discussed above, the proximal nozzle 1201 may include mounts or
mounting lugs that protrude inwardly from the nozzle portions and
extend through corresponding openings 1266 in the outer tube 1260
to be seated in corresponding recesses 1211 in the shaft spine
1210. Thus, to rotate the outer shaft 1260 and spine shaft 1210 and
presumably an end effector (not shown) coupled thereto about the
shaft axis SA-SA relative to the chassis 1240', the clinician
simply rotates the nozzle 1201 as represented by arrows "R" in FIG.
23.
[0163] When sensors are employed at the end effector or at
locations within or on the shaft assembly for example, conductors
such as wires and/or traces (not shown) may be received or mounted
within the outer tube 1260 or could even be routed along the outer
tube 1260 from the sensors to a distal electrical component 1800'
mounted within the nozzle 1201. Thus, the distal electrical
component 1800' is rotatable with the nozzle 1201 and the
wires/traces attached thereto. In the embodiment illustrated in
FIG. 23, the electrical component 1800 comprises a connector,
battery, etc. that includes contacts 1802', 1804', 1806', 1808'
that are laterally displaced from each other.
[0164] The slip ring connector 1600' further includes a laminated
slip ring assembly 1610' that is fabricated from a plurality of
conductive rings that are laminated together. More specifically and
with reference to FIG. 25, one form of slip ring assembly 1610' may
comprise a first non-electrically conductive flange 1670 that forms
a distal end of the slip ring assembly 1610'. The flange 1670 may
be fabricated from a high-heat resistant material, for example. A
first electrically conductive ring 1680 is positioned immediately
adjacent the first flange 1670. The first electrically conductive
ring 1680 may comprise a first copper ring 1681 that has a first
gold plating 1682 thereon. A second non-electrically conductive
ring 1672 is adjacent to the first electrically-conductive ring
1680. A second electrically-conductive ring 1684 is adjacent to the
second non-electrically-conductive ring 1672. The second
electrically-conductive ring 1684 may comprise a second copper ring
1685 that has a second gold plating 1686 thereon. A third
non-electrically-conductive ring 1674 is adjacent to the second
electrically-conductive ring 1684. A third electrically conductive
ring 1688 is adjacent to the third non-electrically conductive ring
1674. The third electrically conductive ring 1688 may comprise a
third copper ring 1689 that has a third gold plating 1690 thereon.
A fourth non-electrically conductive ring 1676 is adjacent to the
third electrically-conductive ring 1688. A fourth electrically
conductive ring 1692 is adjacent to the fourth
non-electrically-conductive ring 1676. The fourth
electrically-conductive ring 1692 is adjacent to the fourth
non-electrically conductive ring 1676. A fifth non-electrically
conductive ring 1678 is adjacent to the fourth
electrically-conductive ring 1692 and forms the proximal end of the
mounting member 1610'. The non-electrically conductive rings 1670,
1672, 1674, 1676, and 1678 may be fabricated from the same
material. The first electrically-conductive ring 1680 forms a first
annular electrically-conductive pathway 1700. The second
electrically-conductive ring 1682 forms a second annular
electrically-conductive pathway 1702 that is laterally or axially
spaced from the first annular electrically-conductive pathway 1700.
The third electrically-conductive ring 1688 forms a third annular
electrically conductive pathway 1704 that is laterally or axially
spaced from the second annular electrically-conductive pathwayl702.
The fourth electrically-conductive ring 1692 forms a fourth annular
electrically-conductive pathway 1706 that is laterally or axially
spaced from the third annular electrically-conductive pathway 1704.
The slip ring assembly 1610' comprises a one piece molded high
temperature resistant, non-conductive material with molded in
channels for electromagnetic forming (EMF--Magneformed) copper
rings.
[0165] As can be seen in FIG. 24, the slip ring connector 1600'
further includes a non-conductive transverse mounting member 1720
that is adapted to be inserted into axially-aligned notches 1710 in
each of the rings 1670, 1680, 1672, 1684, 1674, 1688, 1676, 1692,
and 1678. The transverse mounting member 1720 has a first circuit
trace 1722 thereon that is adapted for electrical contact with the
first annular electrically-conductive pathway 1700 when the
transverse mounting member 1672 is mounted within the notches 1710.
Likewise, a second circuit trace 1724 is printed on the transverse
mounting member 1720 and is configured for electrical contact with
the second annular electrically conductive pathway 1702. A third
circuit trace 1726 is printed on the transverse mounting member
1720 and is configured for electrical contact with the third
annular electrically-conductive pathway 1704. A fourth circuit
trace 1728 is printed on the transverse mounting member 1720 and is
configured for electrical contact with the fourth annular
electrically-conductive pathway 1706.
[0166] In the arrangement depicted in FIGS. 23-25, the slip ring
assembly 1610' is configured to be fixedly (non-rotatably) received
on a mounting hub 1241' on the chassis 1240'. The transverse
mounting member 1720 is received within groove 1243' formed in the
mounting hub 1241' which acts as a keyway for the transverse
mounting member 1720 and which serves to prevent the slip ring
assembly 1610' from rotating relative to the mounting hub
1241'.
[0167] In the depicted embodiment for example, the electrical
component 1800' is mounted within the nozzle 1201 for rotation
about the slip ring assembly 1610' such that: contact 1802' is in
constant electrical contact with the first annular
electrically-conductive path 1700; contact 1804' is in constant
electrical contact with the second annular electrically-conductive
path 1702; contact 1806' is in constant electrical contact with the
third annular electrically-conductive path 1704; and contact 1808'
is in constant electrical contact with the fourth
electrically-conductive path 1706. It will be understood however,
that the various advantages of the slip ring connector 1600' may
also be obtained in applications wherein the slip ring assembly
1610' is supported for rotation about the shaft axis SA-SA and the
electrical component 1800' is fixedly mounted relative thereto. It
will be further appreciated that the slip ring connector 1600' may
be effectively employed in connection with a variety of different
components and applications outside the field of surgery wherein it
is desirable to provide electrical connections between components
that rotate relative to each other.
[0168] The slip ring connector 1600' comprises a radial slip ring
that provides a conductive contact means of passing signal(s) and
power to and from any radial position and after shaft rotation. In
applications wherein the electrical component comprises a battery
contact, the battery contact position can be situated relative to
the mounting member to minimize any tolerance stack-up between
those components. The slip ring connector 1600' represents a low
cost coupling arrangement that can be assembled with minimal
manufacturing costs. The gold plated traces may also minimize the
likelihood of corrosion. The unique and novel contact arrangement
facilitates complete clockwise and counterclockwise rotation about
the shaft axis while remaining in electrical contact with the
corresponding annular electrically-conductive paths.
[0169] FIGS. 26-30 depict another form of electric coupler or slip
ring connector 1600'' that may be employed with, for example an
interchangeable shaft assembly 1200'' or a variety of other
applications that require electrical connections between components
that rotate relative to each other. The shaft assembly 1200'' may
be similar to shaft assemblies 1200 and/or 1200' described herein
except for the differences noted below. The shaft assembly 1200''
may include a closure tube or outer shaft 1260 and a proximal
nozzle 1201 (the upper half of nozzle 1201 is omitted for clarity).
In the illustrated example, the outer shaft 1260 is mounted on a
shaft spine 1210 such that the outer tube 1260 may be selectively
axially movable thereon. The proximal ends of the shaft spine 1210
and the outer tube 1260 may be rotatably coupled to a chassis
1240'' for rotation relative thereto about a shaft axis SA-SA. As
was discussed above, the proximal nozzle 1201 may include mounts or
mounting lugs that protrude inwardly from the nozzle portions and
extend through corresponding openings 1266 in the outer tube 1260
to be seated in corresponding recesses 1211 in the shaft spine
1210. Thus, to rotate the outer shaft 1260 and spine shaft 1210 and
presumably an end effector (not shown) coupled thereto about the
shaft axis SA-SA relative to the chassis 1240'', the clinician
simply rotates the nozzle 1201.
[0170] When sensors are employed at the end effector or at
locations within or on the shaft assembly for example, conductors
such as wires and/or traces (not shown) may be received or mounted
within the outer tube 1260 or could even be routed along the outer
tube 1260 from the sensors to a distal electrical component 1800'''
mounted within the nozzle 1201. In the illustrated embodiment, for
example, the electrical component 1800'' is mounted in the nozzle
1201 such that it is substantially aligned with the shaft axis
SA-SA. The distal electrical component 1800'' is rotatable about
the shaft axis SA-SA with the nozzle 1201 and the wires/traces
attached thereto. The electrical component 1800'' may comprise a
connector, a battery, etc. that includes four contacts 1802'',
1804'', 1806'', 1808'' that are laterally displaced from each
other.
[0171] The slip ring connector 1600'' further includes a slip ring
assembly 1610'' that includes a base ring 1900 that is fabricated
from a non-electrically conductive material and has a central
mounting bore 1902 therethrough. The mounting bore 1902 has a flat
surface 1904 and is configured for non-rotational attachment to a
mounting flange assembly 1930 that is supported at a distal end of
the chassis 1240''. A distal side 1905 of the base ring 1900 has a
series of concentric electrical-conductive rings 1906, 1908, 1910,
and 1912 attached or laminated thereto. The rings 1906, 1908, 1910,
and 1912 may be attached to the base ring 1900 by any suitable
method.
[0172] The base ring 1900 may further include a circuit trace
extending therethrough that is coupled to each of the
electrically-conductive rings 1906, 1908, 1910, and 1912. Referring
now to FIGS. 28-30, a first circuit trace 1922 extends through a
first hole 1920 in the base ring 1900 and is coupled to the first
electrically conductive ring 1906. The first circuit trace 1922
terminates in a first proximal contact portion 1924 on the proximal
side 1907 of the base ring 1900. See FIG. 30. Similarly, a second
circuit trace 1928 extends through a second hole 1926 in the base
ring 1900 and is coupled to the second electrically-conductive ring
1908. The second circuit trace 1928 terminates in a second proximal
contact 1930 on the proximal side 1907 of the base ring 1900. A
third circuit trace 1934 extends through a third hole 1932 in the
base ring and is attached to the third electrically-conductive ring
1910. The third circuit trace 1934 terminates in a third proximal
contact 1936 on the proximal side 1907 of the base ring. A fourth
circuit trace 1940 extends through a fourth hole 1938 in the base
ring 1900 to be attached to the fourth electrically-conductive ring
1912. The fourth circuit trace 1940 terminates in a fourth proximal
contact 1942 on the proximal side 1907 of the base ring 1900.
[0173] Referring now to FIG. 27, the base ring 1900 is configured
to be non-rotatably supported within the nozzle 1201 by a mounting
flange 1950 that is non-rotatably coupled to the mounting hub
portion 1241'' of the chassis 1240''. The mounting hub portion
1241'' may be formed with a flat surface 1243'' for supporting a
transverse mounting member of the type, for example, described
above that includes a plurality (preferably four) leads that may be
coupled to, for example, a circuit board or other corresponding
electrical components supported on the chassis in the various
manners and arrangements described herein as well as in U.S. patent
application Ser. No. 13/803,086. The transverse support member has
been omitted for clarity in FIGS. 26 and 27. However, as can be
seen in FIGS. 26 and 27, the mounting flange 1950 has a notch 1952
therein that is adapted to engage a portion of the flat surface
1243'' on the mounting hub portion 1241''. As can be seen in FIG.
27, the mounting flange 1950 may further include a flange hub
portion 1954 that comprises a series of spring tabs 1956 that serve
to fixedly attach the base ring 1900 to the mounting flange 1950.
It will be understood that the closure tube 1260 and spine 1210
extend through the flange hub 1954 and are rotatable relative
thereto with the nozzle 1201.
[0174] In the depicted embodiment for example, the electrical
component 1800'' is mounted within the nozzle 1201 for rotation
about the slip ring assembly 1610'' such that, for example, contact
1802'' in the component 1800'' is in constant electrical contact
with rings 1906; contact 1804'' is in contact with ring 1908;
contact 1806'' is in contact with ring 1910; and contact 1808'' is
in contact with ring 1912 even when the nozzle 1201 is rotated
relative to the chassis 1240''. It will be understood however, that
the various advantages of the slip ring connector 1600'' may also
be obtained in applications wherein the slip ring assembly 1610''
is supported for rotation about the shaft axis SA-SA and the
electrical component 1800'' is fixedly mounted relative thereto. It
will be further appreciated that the slip ring connector 1600'' may
be effectively employed in connection with a variety of different
components and applications outside the field of surgery wherein it
is desirable to provide electrical connections between components
that rotate relative to each other.
[0175] The slip ring connector 1600'' comprises a radial slip ring
that provides a conductive contact means of passing signal(s) and
power to and from any radial position and after shaft rotation. In
applications wherein the electrical component comprises a battery
contact, the battery contact position can be situated relative to
the mounting member to minimize any tolerance stack-up between
those components. The slip ring connector 1600'' represents a low
cost and compact coupling arrangement that can be assembled with
minimal manufacturing costs. The unique and novel contact
arrangement facilitates complete clockwise and counterclockwise
rotation about the shaft axis while remaining in electrical contact
with the corresponding annular electrically-conductive rings.
[0176] FIGS. 31-36 generally depict a motor-driven surgical
fastening and cutting instrument 2000. As illustrated in FIGS. 31
and 32, the surgical instrument 2000 may include a handle assembly
2002, a shaft assembly 2004, and a power assembly 2006 (or "power
source" or "power pack"). The shaft assembly 2004 may include an
end effector 2008 which, in certain circumstances, can be
configured to act as an endocutter for clamping, severing, and/or
stapling tissue, although, in other instances, different types of
end effectors may be used, such as end effectors for other types of
surgical devices, graspers, cutters, staplers, clip appliers,
access devices, drug/gene therapy devices, ultrasound devices, RF
device, and/or laser devices, for example. Several RF devices may
be found in U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL
HEMOSTATIC DEVICE, which issued on Apr. 4, 1995, and U.S. patent
application Ser. No. 12/031,573, entitled SURGICAL FASTENING AND
CUTTING INSTRUMENT HAVING RF ELECTRODES, filed Feb. 14, 2008. The
entire disclosures of U.S. Pat. No. 5,403,312, entitled
ELECTROSURGICAL HEMOSTATIC DEVICE, which issued on Apr. 4, 1995,
and U.S. patent application Ser. No. 12/031,573, entitled SURGICAL
FASTENING AND CUTTING INSTRUMENT HAVING RF ELECTRODES, filed Feb.
14, 2008, are incorporated herein by reference in their
entirety.
[0177] Referring primarily to FIGS. 32, 33A and 33B, the handle
assembly 2002 can be employed with a plurality of interchangeable
shaft assemblies such as, for example, the shaft assembly 2004.
Such interchangeable shaft assemblies may comprise surgical end
effectors such as, for example, the end effector 2008 that can be
configured to perform one or more surgical tasks or procedures.
Examples of suitable interchangeable shaft assemblies are disclosed
in U.S. Provisional Patent Application Ser. No. 61/782,866,
entitled CONTROL SYSTEM OF A SURGICAL INSTRUMENT, filed Mar. 14,
2013. The entire disclosure of U.S. Provisional Patent Application
Ser. No. 61/782,866, entitled CONTROL SYSTEM OF A SURGICAL
INSTRUMENT, filed Mar. 14, 2013, is hereby incorporated by
reference herein in its entirety.
[0178] Referring primarily to FIG. 32, the handle assembly 2002 may
comprise a housing 2010 that consists of a handle 2012 that may be
configured to be grasped, manipulated and actuated by a clinician.
However, it will be understood that the various unique and novel
arrangements of the various forms of interchangeable shaft
assemblies disclosed herein also may be effectively employed in
connection with robotically-controlled surgical systems. Thus, the
term "housing" also may encompass a housing or similar portion of a
robotic system that houses or otherwise operably supports at least
one drive system that is configured to generate and apply at least
one control motion which could be used to actuate the
interchangeable shaft assemblies disclosed herein and their
respective equivalents. For example, the interchangeable shaft
assemblies disclosed herein may be employed with various robotic
systems, instruments, components and methods disclosed in U.S.
patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING
INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.
Patent Application Publication No. 2012/0298719. U.S. patent
application Ser. No. 13/118,241, entitled SURGICAL STAPLING
INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.
Patent Application Publication No. 2012/0298719 is incorporated by
reference herein in its entirety.
[0179] Referring again to FIG. 32, the handle assembly 2002 may
operably support a plurality of drive systems therein that can be
configured to generate and apply various control motions to
corresponding portions of the interchangeable shaft assembly that
is operably attached thereto. For example, the handle assembly 2002
can operably support a first or closure drive system, which may be
employed to apply closing and opening motions to the shaft assembly
2004 while operably attached or coupled to the handle assembly
2002. In at least one form, the handle assembly 2002 may operably
support a firing drive system that can be configured to apply
firing motions to corresponding portions of the interchangeable
shaft assembly attached thereto.
[0180] Referring primarily to FIGS. 33A and 33B, the handle
assembly 2002 may include a motor 2014 which can be controlled by a
motor driver 2015 and can be employed by the firing system of the
surgical instrument 2000. In various forms, the motor 2014 may be a
DC brushed driving motor having a maximum rotation of,
approximately, 25,000 RPM, for example. In other arrangements, the
motor 2014 may include a brushless motor, a cordless motor, a
synchronous motor, a stepper motor, or any other suitable electric
motor. In certain circumstances, the motor driver 2015 may comprise
an H-Bridge FETs 2019, as illustrated in FIGS. 33A and 33B, for
example. The motor 2014 can be powered by the power assembly 2006
(FIG. 35), which can be releasably mounted to the handle assembly
2002, power assembly 2006 being configured to supply control power
to the surgical instrument 2000. The power assembly 2006 may
comprise a battery 2007 (FIG. 36) which may include a number of
battery cells connected in series that can be used as the power
source to power the surgical instrument 2000. In such
configuration, the power assembly 2006 may be referred to as a
battery pack. In certain circumstances, the battery cells of the
power assembly 2006 may be replaceable and/or rechargeable. In at
least one example, the battery cells can be Lithium-Ion batteries
which can be separably couplable to the power assembly 2006.
[0181] Examples of drive systems and closure systems that are
suitable for use with the surgical instrument 2000 are disclosed in
U.S. Provisional Patent Application Ser. No. 61/782,866, entitled
CONTROL SYSTEM OF A SURGICAL INSTRUMENT, and filed Mar. 14, 2013,
the entire disclosure of which is incorporated by reference herein
in its entirety. For example, the electric motor 2014 can include a
rotatable shaft (not shown) that may operably interface with a gear
reducer assembly that can be mounted in meshing engagement with a
set, or rack, of drive teeth on a longitudinally-movable drive
member. In use, a voltage polarity provided by the battery 2007
(FIG. 36) can operate the electric motor 2014 to drive the
longitudinally-movable drive member to effectuate the end effector
2008. For example, the motor 2014 can be configured to drive the
longitudinally-movable drive member to advance a firing mechanism
to fire staples into tissue captured by the end effector 2008 from
a staple cartridge assembled with the end effector 2008 and/or
advance a cutting member 2011 (FIG. 34) to cut tissue captured by
the end effector 2008, for example.
[0182] In certain circumstances, the surgical instrument 2000 may
comprise a lockout mechanism to prevent a user from coupling
incompatible handle assemblies and power assemblies. For example,
as illustrated in FIG. 35, the power assembly 2006 may include a
mating element 2011. In certain circumstances, the mating element
2011 can be a tab extending from the power assembly 2006. In
certain instances, the handle assembly 2002 may comprise a
corresponding mating element (not shown) for mating engagement with
the mating element 2011. Such an arrangement can be useful in
preventing a user from coupling incompatible handle assemblies and
power assemblies.
[0183] The reader will appreciate that different interchangeable
shaft assemblies may possess different power requirements. The
power required to advance a cutting member through an end effector
and/or to fire staples may depend, for example, on the distance
traveled by the cutting member, the staple cartridge being used,
and/or the type of tissue being treated. That said, the power
assembly 2006 can be configured to meet the power requirements of
various interchangeable shaft assemblies. For example, as
illustrated in FIG. 34, the cutting member 2011 of the shaft
assembly 2004 can be configured to travel a distance D1 along the
end effector 2008. On the other hand, another interchangeable shaft
assembly 2004' may include a cutting member 2011' which can be
configured to travel a distance D2, different from the distance D1,
along an end effector 2008' of the interchangeable shaft assembly
2004'. The power assembly 2006 can be configured to provide a first
power output sufficient to power the motor 2014 to advance the
cutting member 2011 the distance D1 while the interchangeable shaft
assembly 2004 is coupled to the handle assembly 2002 and can be
configured to provide a second power output, different from the
first power output, which is sufficient to power the motor 2014 to
advance the cutting member 2011' the distance D2 while the
interchangeable shaft assembly 2004' is coupled to the handle
assembly 2002, for example. As illustrated in FIGS. 33A and 33B and
as described below in greater detail, the power assembly 2006 may
include a power management controller 2016 (FIG. 36) which can be
configured to modulate the power output of the power assembly 2006
to deliver a first power output to power the motor 2014 to advance
the cutting member 2011 the distance D1 while the interchangeable
shaft assembly 2004 is coupled to the handle assembly 2002 and to
deliver a second power output to power the motor 2014 to advance
the cutting member 2011' the distance D2 while the interchangeable
shaft assembly 2004' is coupled to the handle assembly 2002, for
example. Such modulation can be beneficial in avoiding transmission
of excessive power to the motor 2014 beyond the requirements of an
interchangeable shaft assembly that is coupled to the handle
assembly 2002.
[0184] Referring again to FIGS. 32-36, the handle assembly 2002 can
be releasably coupled or attached to an interchangeable shaft
assembly such as, for example, the shaft assembly 2004. In certain
instances, the handle assembly 2002 can be releasably coupled or
attached to the power assembly 2006. Various coupling means can be
utilized to releasably couple the handle assembly 2002 to the shaft
assembly 2004 and/or to the power assembly 2006. Exemplary coupling
mechanisms are described in U.S. Provisional Patent Application
Ser. No. 61/782,866, entitled CONTROL SYSTEM OF A SURGICAL
INSTRUMENT, and filed Mar. 14, 2013. For example, the shaft
assembly 2004 may include a shaft attachment module 2018 (FIG. 32)
which may further include a latch actuator assembly that may be
configured to cooperate with a lock yoke that is pivotally coupled
to the shaft attachment module 2018 for selective pivotal travel
relative thereto, wherein the lock yoke may include proximally
protruding lock lugs that are configured for releasable engagement
with corresponding lock detents or grooves formed in a hand
assembly attachment module 2020 of the handle assembly 2002.
[0185] Referring now primarily to FIGS. 33A-36, the shaft assembly
2004 may include a shaft assembly controller 2022 which can
communicate with the power management controller 2016 through an
interface 2024 while the shaft assembly 2004 and the power assembly
2006 are coupled to the handle assembly 2002. For example, the
interface 2024 may comprise a first interface portion 2025 which
may include one or more electric connectors 2026 for coupling
engagement with corresponding shaft assembly electric connectors
2028 and a second interface portion 2027 which may include one or
more electric connectors 2030 for coupling engagement with
corresponding power assembly electric connectors 2032 to permit
electrical communication between the shaft assembly controller 2022
and the power management controller 2016 while the shaft assembly
2004 and the power assembly 2006 are coupled to the handle assembly
2002. One or more communication signals can be transmitted through
the interface 2024 to communicate one or more of the power
requirements of the attached interchangeable shaft assembly 2004 to
the power management controller 2016. In response, the power
management controller may modulate the power output of the battery
2007 of the power assembly 2006, as described below in greater
detail, in accordance with the power requirements of the attached
shaft assembly 2004. In certain circumstances, one or more of the
electric connectors 2026, 2028, 2030, and/or 2032 may comprise
switches which can be activated after mechanical coupling
engagement of the handle assembly 2002 to the shaft assembly 2004
and/or to the power assembly 2006 to allow electrical communication
between the shaft assembly controller 2022 and the power management
controller 2016.
[0186] In certain circumstances, the interface 2024 can facilitate
transmission of the one or more communication signals between the
power management controller 2016 and the shaft assembly controller
2022 by routing such communication signals through a main
controller 2017 (FIGS. 33A and 33B) residing in the handle assembly
2002, for example. In other circumstances, the interface 2024 can
facilitate a direct line of communication between the power
management controller 2016 and the shaft assembly controller 2022
through the handle assembly 2002 while the shaft assembly 2004 and
the power assembly 2006 are coupled to the handle assembly
2002.
[0187] In one instance, the main microcontroller 2017 may be any
single core or multicore processor such as those known under the
trade name ARM Cortex by Texas Instruments. In one instance, the
surgical instrument 2000 may comprise a power management controller
2016 such as, for example, a safety microcontroller platform
comprising two microcontroller-based families such as TMS570 and
RM4x known under the trade name Hercules ARM Cortex R4, also by
Texas Instruments. Nevertheless, other suitable substitutes for
microcontrollers and safety processor may be employed, without
limitation. In one instance, the safety processor 1004 may be
configured specifically for IEC 61508 and ISO 26262 safety critical
applications, among others, to provide advanced integrated safety
features while delivering scalable performance, connectivity, and
memory options.
[0188] In certain instances, the microcontroller 2017 may be an LM
4F230H5QR, available from Texas Instruments, for example. In at
least one example, the Texas Instruments LM4F230H5QR is an ARM
Cortex-M4F Processor Core comprising on-chip memory of 256 KB
single-cycle flash memory, or other non-volatile memory, up to 40
MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB
single-cycle serial random access memory (SRAM), internal read-only
memory (ROM) loaded with StellarisWare.RTM. software, 2 KB
electrically erasable programmable read-only memory (EEPROM), one
or more pulse width modulation (PWM) modules, one or more
quadrature encoder inputs (QED analog, one or more 12-bit
Analog-to-Digital Converters (ADC) with 12 analog input channels,
among other features that are readily available for the product
datasheet. The present disclosure should not be limited in this
context.
[0189] Referring now primarily to FIGS. 36 and 37, the power
assembly 2006 may include a power management circuit 2034 which may
comprise the power management controller 2016, a power modulator
2038, and a current sense circuit 2036. The power management
circuit 2034 can be configured to modulate power output of the
battery 2007 based on the power requirements of the shaft assembly
2004 while the shaft assembly 2004 and the power assembly 2006 are
coupled to the handle assembly 2002. For example, the power
management controller 2016 can be programmed to control the power
modulator 2038 of the power output of the power assembly 2006 and
the current sense circuit 2036 can be employed to monitor power
output of the power assembly 2006 to provide feedback to the power
management controller 2016 about the power output of the battery
2007 so that the power management controller 2016 may adjust the
power output of the power assembly 2006 to maintain a desired
output, as illustrated in FIG. 37.
[0190] It is noteworthy that the power management controller 2016
and/or the shaft assembly controller 2022 each may comprise one or
more processors and/or memory units which may store a number of
software modules. Although certain modules and/or blocks of the
surgical instrument 2000 may be described by way of example, it can
be appreciated that a greater or lesser number of modules and/or
blocks may be used. Further, although various instances may be
described in terms of modules and/or blocks to facilitate
description, such modules and/or blocks may be implemented by one
or more hardware components, e.g., processors, Digital Signal
Processors (DSPs), Programmable Logic Devices (PLDs), Application
Specific Integrated Circuits (ASICs), circuits, registers and/or
software components, e.g., programs, subroutines, logic and/or
combinations of hardware and software components.
[0191] In certain instances, the surgical instrument 2000 may
comprise an output device 2042 which may include one or more
devices for providing a sensory feedback to a user. Such devices
may comprise, for example, visual feedback devices (e.g., an LCD
display screen, LED indicators), audio feedback devices (e.g., a
speaker, a buzzer) or tactile feedback devices (e.g., haptic
actuators). In certain circumstances, the output device 2042 may
comprise a display 2043 which may be included in the handle
assembly 2002, as illustrated in FIG. 36. The shaft assembly
controller 2022 and/or the power management controller 2016 can
provide feedback to a user of the surgical instrument 2000 through
the output device 2042. The interface 2024 can be configured to
connect the shaft assembly controller 2022 and/or the power
management controller 2016 to the output device 2042. The reader
will appreciate that the output device 2042 can instead be
integrated with the power assembly 2006. In such circumstances,
communication between the output device 2042 and the shaft assembly
controller 2022 may be accomplished through the interface 2024
while the shaft assembly 2004 is coupled to the handle assembly
2002.
[0192] Referring to FIGS. 38 and 39, a surgical instrument 2050 is
illustrated. The surgical instrument 2050 is similar in many
respects to the surgical fastening and cutting instrument 2000
(FIG. 31). For example, the surgical instrument 2050 may include an
end effector 2052 which is similar in many respects to the end
effector 2008. For example, the end effector 2052 can be configured
to act as an endocutter for clamping, severing, and/or stapling
tissue.
[0193] Further to the above, the surgical instrument 2050 may
include an interchangeable working assembly 2054 which may include
a handle assembly 2053 and a shaft 2055 extending between the
handle assembly 2053 and the end effector 2052, as illustrated in
FIG. 38. In certain instances, the surgical instrument 2050 may
include a power assembly 2056 which can be employed with a
plurality of interchangeable working assemblies such as, for
example, the interchangeable working assembly 2054. Such
interchangeable working assemblies may include surgical end
effectors such as, for example, the end effector 2052 that can be
configured to perform one or more surgical tasks or procedures. In
certain circumstances, the handle assembly 2053 and the shaft 2055
may be integrated into a single unit. In other circumstances, the
handle assembly 2053 and the shaft 2055 may be separably couplable
to each other.
[0194] Similar to the surgical instrument 2000, the surgical
instrument 2050 may operably support a plurality of drive systems
which can be powered by the power assembly 2056 while the power
assembly 2056 is coupled to the interchangeable working assembly
2054. For example, the interchangeable working assembly 2054 can
operably support a closure drive system, which may be employed to
apply closing and opening motions to the end effector 2052. In at
least one form, the interchangeable working assembly 2054 may
operably support a firing drive system that can be configured to
apply firing motions to the end effector 2052. Examples of drive
systems suitable for use with the surgical instrument 2050 are
described in U.S. Provisional Patent Application Ser. No.
61/782,866, entitled CONTROL SYSTEM OF A SURGICAL INSTRUMENT, and
filed Mar. 14, 2013, the entire disclosure of which is incorporated
by reference herein in its entirety.
[0195] Referring to FIG. 39, the power assembly 2056 of the
surgical instrument 2050 can be separably coupled to an
interchangeable working assembly such as, for example, the
interchangeable working assembly 2054. Various coupling means can
be utilized to releasably couple the power assembly 2056 to the
interchangeable working assembly 2054. Exemplary coupling
mechanisms are described herein and are described in U.S.
Provisional Patent Application Ser. No. 61/782,866, entitled
CONTROL SYSTEM OF A SURGICAL INSTRUMENT, and filed Mar. 14, 2013,
the entire disclosure of which is incorporated by reference herein
in its entirety.
[0196] Still referring to FIG. 39, the power assembly 2056 may
include a power source 2058 such as, for example, a battery which
can be configured to power the interchangeable working assembly
2054 while coupled to the power assembly 2056. In certain
instances, the power assembly 2056 may include a memory 2060 which
can be configured to receive and store information about the
battery 2058 and/or the interchangeable working assembly 2054 such
as, for example, the state of charge of the battery 2058, the
number of treatment cycles performed using the battery 2058, and/or
identification information for the interchangeable working
assemblies coupled to the power assembly 2056 during the life cycle
of the battery 2058. Further to the above, the interchangeable
working assembly 2054 may include a controller 2062 which can be
configured to provide the memory 2060 with such information about
the battery 2058 and/or the interchangeable working assembly
2054.
[0197] Still referring to FIG. 39, the power assembly 2056 may
include an interface 2064 which can be configured to facilitate
electrical communication between the memory 2060 of the power
assembly 2056 and a controller of an interchangeable working
assembly that is coupled to the power assembly 2056 such as, for
example, the controller 2062 of the interchangeable working
assembly 2054. For example, the interface 2064 may comprise one or
more connectors 2066 for coupling engagement with corresponding
working assembly connectors 2068 to permit electrical communication
between the controller 2062 and the memory 2060 while the
interchangeable working assembly 2054 is coupled to the power
assembly 2056. In certain circumstances, one or more of the
electric connectors 2066 and/or 2068 may comprise switches which
can be activated after coupling engagement of the interchangeable
working assembly 2054 and the power assembly 2056 to allow electric
communication between the controller 2062 and the memory 2060.
[0198] Still referring to FIG. 39, the power assembly 2056 may
include a state of charge monitoring circuit 2070. In certain
circumstances, the state of charge monitoring circuit 2070 may
comprise a coulomb counter. The controller 2062 can be in
communication with the state of charge monitoring circuit 2070
while the interchangeable working assembly 2054 is coupled to the
power assembly 2056. The state of charge monitoring circuit 2070
can be operable to provide for accurate monitoring of charge states
of the battery 2058.
[0199] FIG. 40 depicts an exemplary module 2072 for use with a
controller of an interchangeable working assembly such as, for
example, the controller 2062 of the interchangeable working
assembly 2054 while coupled to the power assembly 2056. For
example, the controller 2062 may comprise one or more processors
and/or memory units which may store a number of software modules
such as, for example, the module 2072. Although certain modules
and/or blocks of the surgical instrument 2050 may be described by
way of example, it can be appreciated that a greater or lesser
number of modules and/or blocks may be used. Further, although
various instances may be described in terms of modules and/or
blocks to facilitate description, such modules and/or blocks may be
implemented by one or more hardware components, e.g., processors,
DSPs, PLDs, ASICs, circuits, registers and/or software components,
e.g., programs, subroutines, logic and/or combinations of hardware
and software components.
[0200] In any event, upon coupling the interchangeable working
assembly 2054 to the power assembly 2056, the interface 2064 may
facilitate communication between the controller 2062 and the memory
2060 and/or the state of charge monitoring circuit 2070 to execute
the module 2072, as illustrated in FIG. 40. For example, the
controller 2062 of the interchangeable working assembly 2054 may
utilize the state of charge monitoring circuit 2070 to measure the
state of charge of the battery 2058. The controller 2062 may then
access the memory 2060 and determine whether a previous value for
the state of charge of the battery 2058 is stored in the memory
2060. When a previous value is detected, the controller 2060 may
compare the measured value to the previously stored value. When the
measured value is different from the previously stored value, the
controller 2060 may update the previously stored value. When no
value is previously recorded, the controller 2060 may store the
measured value into the memory 2060. In certain circumstances, the
controller 2060 may provide visual feedback to a user of the
surgical instrument 2050 as to the measured state of charge of the
battery 2058. For example, the controller 2060 may display the
measured value of the state of charge of the battery 2058 on an LCD
display screen which, in some circumstances, can be integrated with
the interchangeable working assembly 2054.
[0201] Further to the above, the module 2072 also can be executed
by other controllers upon coupling the interchangeable working
assemblies of such other controllers to the power assembly 2056.
For example, a user may disconnect the interchangeable working
assembly 2054 from the power assembly 2056. The user may then
connect another interchangeable working assembly comprising another
controller to the power assembly 2056. Such controller may in turn
utilize the coulomb counting circuit 2070 to measure the state of
charge of the battery 2058 and may then access the memory 2060 and
determine whether a previous value for the state of charge of the
battery 2058 is stored in the memory 2060 such as, for example, a
value entered by the controller 2060 while the interchangeable
working assembly 2054 was coupled to the power assembly 2056. When
a previous value is detected, the controller may compare the
measured value to the previously stored value. When the measured
value is different from the previously stored value, the controller
may update the previously stored value.
[0202] FIG. 41 depicts a surgical instrument 2090 which is similar
in many respects to the surgical instrument 2000 (FIG. 31) and/or
the surgical instrument 2050 (FIG. 38). For example, the surgical
instrument 2090 may include an end effector 2092 which is similar
in many respects to the end effector 2008 and/or the end effector
2052. For example, the end effector 2092 can be configured to act
as an endocutter for clamping, severing, and/or stapling
tissue.
[0203] Further to the above, the surgical instrument 2090 may
include an interchangeable working assembly 2094 which may include
a handle assembly 2093 and a shaft 2095 which may extend between
the handle assembly 2093 and the end effector 2092. In certain
instances, the surgical instrument 2090 may include a power
assembly 2096 which can be employed with a plurality of
interchangeable working assemblies such as, for example, the
interchangeable working assembly 2094. Such interchangeable working
assemblies may comprise surgical end effectors such as, for
example, the end effector 2092 that can be configured to perform
one or more surgical tasks or procedures. In certain circumstances,
the handle assembly 2093 and the shaft 2095 may be integrated into
a single unit. In other circumstances, the handle assembly 2093 and
the shaft 2095 can be separably couplable to each other.
[0204] Furthermore, the power assembly 2096 of the surgical
instrument 2090 can be separably couplable to an interchangeable
working assembly such as, for example, the interchangeable working
assembly 2094. Various coupling means can be utilized to releasably
couple the power assembly 2096 to the interchangeable working
assembly 2094. Similar to the surgical instrument 2050 and/or the
surgical instrument 2000, the surgical instrument 2090 may operably
support one or more drive systems which can be powered by the power
assembly 2096 while the power assembly 2096 is coupled to the
interchangeable working assembly 2094. For example, the
interchangeable working assembly 2094 may operably support a
closure drive system, which may be employed to apply closing and/or
opening motions to the end effector 2092. In at least one form, the
interchangeable working assembly 2094 may operably support a firing
drive system that can be configured to apply firing motions to the
end effector 2092. Exemplary drive systems and coupling mechanisms
for use with the surgical instrument 2090 are described in greater
detail U.S. Provisional Patent Application Ser. No. 61/782,866,
entitled CONTROL SYSTEM OF A SURGICAL INSTRUMENT, and filed Mar.
14, 2013, the entire disclosure of which is incorporated by
reference herein in its entirety.
[0205] Referring to FIGS. 41-45, the interchangeable working
assembly 2094 may include a motor such as, for example, the motor
2014 (FIG. 44) and a motor driver such as, for example, the motor
driver 2015 (FIG. 44) which can be employed to motivate the closure
drive system and/or the firing drive system of the interchangeable
working assembly 2094, for example. The motor 2014 can be powered
by a battery 2098 (FIG. 42) which may reside in the power assembly
2096. As illustrated in FIGS. 42 and 43, the battery 2098 may
include a number of battery cells connected in series that can be
used as a power source to power the motor 2014. In certain
instances, the battery cells of the power assembly 2096 may be
replaceable and/or rechargeable. The battery cells can be
Lithium-Ion batteries which can be separably couplable to the power
assembly 2096, for example. In use, a voltage polarity provided by
the power assembly 2096 can operate the motor 2014 to drive a
longitudinally-movable drive member to effectuate the end effector
2092. For example, the motor 2014 can be configured to drive the
longitudinally-movable drive member to advance a cutting member to
cut tissue captured by the end effector 2092 and/or a firing
mechanism to fire staples from a staple cartridge assembled with
the end effector 2092, for example. The staples can be fired into
tissue captured by the end effector 2092, for example.
[0206] Referring now to FIGS. 41-45, the interchangeable working
assembly 2094 may include a working assembly controller 2102 (FIGS.
44 and 45) and the power assembly 2096 may include a power assembly
controller 2100 (FIGS. 42 and 43). The working assembly controller
2102 can be configured to generate one or more signals to
communicate with the power assembly controller 2100. In certain
instances, the working assembly controller 2102 may generate the
one or more signals to communicate with the power assembly
controller 2100 by modulating power transmission from the power
assembly 2096 to the interchangeable working assembly 2094 while
the power assembly 2096 is coupled to the interchangeable working
assembly 2094.
[0207] Furthermore, the power assembly controller 2100 can be
configured to perform one or more functions in response to
receiving the one or more signals generated by the working assembly
controller 2102. For example, the interchangeable working assembly
2094 may comprise a power requirement and the working assembly
controller 2102 may be configured to generate a signal to instruct
the power assembly controller 2100 to select a power output of the
battery 2098 in accordance with the power requirement of the
interchangeable working assembly 2094; the signal can be generated,
as described above, by modulating power transmission from the power
assembly 2096 to the interchangeable working assembly 2094 while
the power assembly 2096 is coupled to the interchangeable working
assembly 2094. In response to receiving the signal, the power
assembly controller 2100 may set the power output of the battery
2098 to accommodate the power requirement of the interchangeable
working assembly 2094. The reader will appreciate that various
interchangeable working assemblies may be utilized with the power
assembly 2096. The various interchangeable working assemblies may
comprise various power requirements and may generate signals unique
to their power requirements during their coupling engagement with
the power assembly 2096 to alert the power assembly controller 2100
to set the power output of the battery 2098 in accordance with
their power requirements.
[0208] Referring now primarily to FIGS. 42 and 43, the power
assembly 2096 may include a power modulator control 2106 which may
comprise, for example, one or more field-effect transistors (FETs),
a Darlington array, an adjustable amplifier, and/or any other power
modulator. The power assembly controller 2100 may actuate the power
modulator control 2106 to set the power output of the battery 2098
to the power requirement of the interchangeable working assembly
2094 in response to the signal generated by working assembly
controller 2102 while the interchangeable working assembly 2094 is
coupled to the power assembly 2096.
[0209] Still referring primarily to FIGS. 42 and 43, the power
assembly controller 2100 can be configured to monitor power
transmission from the power assembly 2096 to the interchangeable
working assembly 2094 for the one or more signals generated by the
working assembly controller 2102 of the interchangeable working
assembly 2094 while he interchangeable working assembly 2094 is
coupled to the power assembly 2096. As illustrated in FIG. 42, the
power assembly controller 2100 may utilize a voltage monitoring
mechanism for monitoring the voltage across the battery 2098 to
detect the one or more signals generated by the working assembly
controller 2102, for example. In certain instances, a voltage
conditioner can be utilized to scale the voltage of the battery
2098 to be readable by an Analog to Digital Converter (ADC) of the
power assembly controller 2100. As illustrated in FIG. 42, the
voltage conditioner may comprise a voltage divider 2108 which can
create a reference voltage or a low voltage signal proportional to
the voltage of the battery 2098 which can be measured and reported
to the power assembly controller 2100 through the ADC, for
example.
[0210] In other circumstances, as illustrated in FIG. 43, the power
assembly 2096 may comprise a current monitoring mechanism for
monitoring current transmitted to the interchangeable working
assembly 2094 to detect the one or more signals generated by the
working assembly controller 2102, for example. In certain
instances, the power assembly 2096 may comprise a current sensor
2110 which can be utilized to monitor current transmitted to the
interchangeable working assembly 2094. The monitored current can be
reported to the power assembly controller 2100 through an ADC, for
example. In other circumstances, the power assembly controller 2100
may be configured to simultaneously monitor both of the current
transmitted to the interchangeable working assembly 2094 and the
corresponding voltage across the battery 2098 to detect the one or
more signals generated by the working assembly controller 2102. The
reader will appreciate that various other mechanisms for monitoring
current and/or voltage can be utilized by the power assembly
controller 2100 to detect the one or more signals generated by the
working assembly controller 2102; all such mechanisms are
contemplated by the present disclosure.
[0211] As illustrated in FIG. 44, the working assembly controller
2102 can be configured to generate the one or more signals for
communication with the power assembly controller 2100 by
effectuating the motor driver 2015 to modulate the power
transmitted to the motor 2014 from the battery 2098. In result, the
voltage across the battery 2098 and/or the current drawn from the
battery 2098 to power the motor 2014 may form discrete patterns or
waveforms that represent the one or more signals. As described
above, the power assembly controller 2100 can be configured to
monitor the voltage across the battery 2098 and/or the current
drawn from the battery 2098 for the one or more signals generated
by the working assembly controller 2102.
[0212] Upon detecting a signal, the power assembly controller 2100
can be configured to perform one or more functions that correspond
to the detected signal. In at least one example, upon detecting a
first signal, the power assembly controller 2100 can be configured
to actuate the power modulator control 2106 to set the power output
of the battery 2098 to a first duty cycle. In at least one example,
upon detecting a second signal, the power assembly controller 2100
can be configured to actuate the power modulator control 2106 to
set the power output of the battery 2098 to a second duty cycle
different from the first duty cycle.
[0213] In certain circumstances, as illustrated in FIG. 45, the
interchangeable working assembly 2094 may include a power
modulation circuit 2012 which may comprise one or more field-effect
transistors (FETs) which can be controlled by the working assembly
controller 2102 to generate a signal or a waveform recognizable by
the power assembly controller 2100. For example, in certain
circumstances, the working assembly controller 2102 may operate the
power modulation circuit 2012 to amplify the voltage higher than
the voltage of the battery 2098 to trigger a new power mode of the
power assembly 2096, for example.
[0214] Referring now primarily to FIGS. 42 and 43, the power
assembly 2096 may comprise a switch 2104 which can be switchable
between an open position and a closed position. The switch 2104 can
be transitioned from the open position to the closed positioned
when the power assembly 2096 is coupled with the interchangeable
working assembly 2094, for example. In certain instances, the
switch 2104 can be manually transitioned from the open position to
the closed position after the power assembly 2096 is coupled with
the interchangeable working assembly 2094, for example. While the
switch 2104 is in the open position, components of the power
assembly 2096 may draw sufficiently low or no power to retain
capacity of the battery 2098 for clinical use. The switch 2104 can
be a mechanical, reed, hall, or any other suitable switching
mechanism. Furthermore, in certain circumstances, the power
assembly 2096 may include an optional power supply 2105 which may
be configured to provide sufficient power to various components of
the power assembly 2096 during use of the battery 2098. Similarly,
the interchangeable working assembly 2094 also may include an
optional power supply 2107 which can be configured to provide
sufficient power to various components of the interchangeable
working assembly 2094.
[0215] In use, as illustrated in FIG. 46, the power assembly 2096
can be coupled to the interchangeable working assembly 2094. In
certain instances, as described above, the switch 2104 can be
transitioned to the closed configuration to electrically connect
the interchangeable working assembly 2094 to the power assembly
2096. In response, the interchangeable working assembly 2094 may
power up and may, at least initially, draw relatively low current
from the battery 2098. For example, the interchangeable working
assembly 2094 may draw less than or equal to 1 ampere to power
various components of the interchangeable working assembly 2094. In
certain instances, the power assembly 2096 also may power up as the
switch 2014 is transitioned to the closed position. In response,
the power assembly controller 2100 may begin to monitor current
draw from the interchangeable working assembly 2094, as described
in greater detail above, by monitoring voltage across the battery
2098 and/or current transmission from the battery 2098 to the
interchangeable working assembly 2094, for example.
[0216] To generate and transmit a communication signal to the power
assembly controller 2100 via power modulation, the working assembly
controller 2102 may employ the motor drive 2015 to pulse power to
the motor 2014 in patterns or waveforms of power spikes, for
example. In certain circumstances, the working assembly controller
2102 can be configured to communicate with the motor driver 2015 to
rapidly switch the direction of motion of the motor 2014 by rapidly
switching the voltage polarity across the windings of the motor
2014 to limit the effective current transmission to the motor 2014
resulting from the power spikes. In result, as illustrated in FIG.
47C, the effective motor displacement resulting from the power
spikes can be reduced to minimize effective displacement of a drive
system of the surgical instrument 2090 that is coupled to the motor
2014 in response to the power spikes.
[0217] Further to the above, the working assembly controller 2102
may communicate with the power assembly controller 2100 by
employing the motor driver 2015 to draw power from the battery 2098
in spikes arranged in predetermined packets or groups which can be
repeated over predetermined time periods to form patterns
detectable by the power assembly controller 2100. For example, as
illustrated in FIGS. 47A and 47B, the power assembly controller
2100 can be configured to monitor voltage across the battery 2100
for predetermined voltage patterns such as, for example, the
voltage pattern 2103 (FIG. 47A) and/or predetermined current
patterns such as, for example, the current pattern 2109 (FIG. 47B)
using voltage and/or current monitoring mechanisms as described in
greater detail above. Furthermore, the power assembly controller
2100 can be configured to perform one or more functions upon
detecting of a pattern. The reader will appreciate that the
communication between the power assembly controller 2100 and the
working assembly controller 2102 via power transmission modulation
may reduce the number of connection lines needed between the
interchangeable working assembly 2094 and the power assembly
2096.
[0218] In certain circumstances, the power assembly 2096 can be
employed with various interchangeable working assemblies of
multiple generations which may comprise different power
requirements. Some of the various interchangeable workings
assemblies may comprise communication systems, as described above,
while others may lack such communication systems. For example, the
power assembly 2096 can be utilized with a first generation
interchangeable working assembly which lacks the communication
system described above. Alternatively, the power assembly 2096 can
be utilized with a second generation interchangeable working
assembly such as, for example, the interchangeable working assembly
2094 which comprises a communication system, as described
above.
[0219] Further to the above, the first generation interchangeable
working assembly may comprise a first power requirement and the
second generation interchangeable working assembly may comprise a
second power requirement which can be different from the first
power requirement. For example, the first power requirement may be
less than the second power requirement. To accommodate the first
power requirement of the first generation interchangeable working
assembly and the second power requirement of the second generation
interchangeable working assembly, the power assembly 2096 may
comprise a first power mode for use with the first generation
interchangeable working assembly and a second power mode for use
with the second generation interchangeable working assembly. In
certain instances, the power assembly 2096 can be configured to
operate at a default first power mode corresponding to the power
requirement of the first generation interchangeable working
assembly. As such, when a first generation interchangeable working
assembly is connected to the power assembly 2096, the default first
power mode of the power assembly 2096 may accommodate the first
power requirement of the first generation interchangeable working
assembly. However, when a second generation interchangeable working
assembly such as, for example, the interchangeable working assembly
2094 is connected to the power assembly 2096, the working assembly
controller 2102 of the interchangeable working assembly 2094 may
communicate, as described above, with the power assembly controller
2100 of the power assembly 2096 to switch the power assembly 2096
to the second power mode to accommodate the second power
requirement of the interchangeable working assembly 2094. The
reader will appreciate that since the first generation
interchangeable working assembly lacks the ability to generate a
communication signal, the power assembly 2096 will remain in the
default first power mode while connected to the first generation
interchangeable working assembly.
[0220] As described above, the battery 2098 can be rechargeable. In
certain circumstances, it may be desirable to drain the battery
2098 prior to shipping the power assembly 2096. A dedicated
drainage circuit can be activated to drain the battery 2098 in
preparation for shipping of the power assembly 2096. Upon reaching
its final destination, the battery 2098 can be recharged for use
during a surgical procedure. However, the drainage circuit may
continue to consume energy from the battery 2098 during clinical
use. In certain circumstances, the interchangeable working assembly
controller 2102 can be configured to transmit a drainage circuit
deactivation signal to the power assembly controller 2100 by
modulating power transmission from the battery 2098 to the motor
2014, as described in greater detail above. The power assembly
controller 2100 can be programmed to deactivate the drainage
circuit to prevent drainage of the battery 2098 by the drainage
circuit in response to the drainage circuit deactivation signal,
for example. The reader will appreciate that various communication
signals can be generated by the working assembly controller 2102 to
instruct the power assembly controller 2100 to perform various
functions while the power assembly 2096 is coupled to the
interchangeable working assembly 2094.
[0221] Referring again to FIGS. 42-45, the power assembly
controller 2100 and/or the working assembly controller 2102 may
comprise one or more processors and/or memory units which may store
a number of software modules. Although certain modules and/or
blocks of the surgical instrument 2050 may be described by way of
example, it can be appreciated that a greater or lesser number of
modules and/or blocks may be used. Further, although various
instances may be described in terms of modules and/or blocks to
facilitate description, such modules and/or blocks may be
implemented by one or more hardware components, e.g., processors,
DSPs, PLDs, ASICs, circuits, registers and/or software components,
e.g., programs, subroutines, logic and/or combinations of hardware
and software components.
[0222] FIG. 48 generally depicts a motor-driven surgical instrument
2200. In certain circumstances, the surgical instrument 2200 may
include a handle assembly 2202, a shaft assembly 2204, and a power
assembly 2206 (or "power source" or "power pack"). The shaft
assembly 2204 may include an end effector 2208 which, in certain
circumstances, can be configured to act as an endocutter for
clamping, severing, and/or stapling tissue, although, in other
circumstances, different types of end effectors may be used, such
as end effectors for other types of surgical devices, graspers,
cutters, staplers, clip appliers, access devices, drug/gene therapy
devices, ultrasound, RF and/or laser devices, etc. Several RF
devices may be found in U.S. Pat. No. 5,403,312, entitled
ELECTROSURGICAL HEMOSTATIC DEVICE, which issued on Apr. 4, 1995,
and U.S. patent application Ser. No. 12/031,573, entitled SURGICAL
FASTENING AND CUTTING INSTRUMENT HAVING RF ELECTRODES, filed Feb.
14, 2008, the entire disclosures of which are incorporated herein
by reference in their entirety.
[0223] In certain circumstances, the handle assembly 2202 can be
separably couplable to the shaft assembly 2204, for example. In
such circumstances, the handle assembly 2202 can be employed with a
plurality of interchangeable shaft assemblies which may comprise
surgical end effectors such as, for example, the end effector 2208
that can be configured to perform one or more surgical tasks or
procedures. For example, one or more of the interchangeable shaft
assemblies may employ end effectors that are adapted to support
different sizes and types of staple cartridges, have different
shaft lengths, sizes, and types, etc. Examples of suitable
interchangeable shaft assemblies are disclosed in U.S. Provisional
Patent Application Ser. No. 61/782,866, entitled CONTROL SYSTEM OF
A SURGICAL INSTRUMENT, and filed Mar. 14, 2013, the entire
disclosure of which is hereby incorporated by reference herein in
its entirety.
[0224] Referring still to FIG. 48, the handle assembly 2202 may
comprise a housing 2210 that consists of a handle 2212 that may be
configured to be grasped, manipulated, and/or actuated by a
clinician. However, it will be understood that the various unique
and novel arrangements of the housing 2210 also may be effectively
employed in connection with robotically-controlled surgical
systems. Thus, the term "housing" also may encompass a housing or
similar portion of a robotic system that houses or otherwise
operably supports at least one drive system that is configured to
generate and apply at least one control motion which could be used
to actuate the shaft assembly 2204 disclosed herein and its
respective equivalents. For example, the housing 2210 disclosed
herein may be employed with various robotic systems, instruments,
components and methods disclosed in U.S. patent application Ser.
No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH
ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Patent
Application Publication No. 2012/0298719, which is incorporated by
reference herein in its entirety.
[0225] In at least one form, the surgical instrument 2200 may be a
surgical fastening and cutting instrument. Furthermore, the housing
2210 may operably support one or more drive systems. For example,
as illustrated in FIG. 50, the housing 2210 may support a drive
system referred to herein as firing drive system 2214 that is
configured to apply firing motions to the end effector 2208. The
firing drive system 2214 may employ an electric motor 2216, which
can be located in the handle 2212, for example. In various forms,
the motor 2216 may be a DC brushed driving motor having a maximum
rotation of, approximately, 25,000 RPM, for example. In other
arrangements, the motor may include a brushless motor, a cordless
motor, a synchronous motor, a stepper motor, or any other suitable
electric motor. A battery 2218 (or "power source" or "power pack"),
such as a Li ion battery, for example, may be coupled to the handle
2212 to supply power to a control circuit board assembly 2220 and
ultimately to the motor 2216.
[0226] In certain circumstances, referring still to FIG. 50, the
electric motor 2216 can include a rotatable shaft (not shown) that
may operably interface with a gear reducer assembly 2222 that may
be mounted in meshing engagement with a with a set, or rack, of
drive teeth 2224 on a longitudinally-movable drive member 2226. In
use, a voltage polarity provided by the battery 2218 can operate
the electric motor 2216 in a clockwise direction wherein the
voltage polarity applied to the electric motor by the battery 2218
can be reversed in order to operate the electric motor 2216 in a
counter-clockwise direction. When the electric motor 2216 is
rotated in one direction, the drive member 2226 will be axially
driven in a distal direction "D", for example, and when the motor
2216 is driven in the opposite rotary direction, the drive member
2226 will be axially driven in a proximal direction "P", for
example, as illustrated in FIG. 50. The handle 2212 can include a
switch which can be configured to reverse the polarity applied to
the electric motor 2216 by the battery 2218. As with the other
forms described herein, the handle 2212 also can include a sensor
that is configured to detect the position of the drive member 2226
and/or the direction in which the drive member 2226 is being
moved.
[0227] As indicated above, in at least one form, the longitudinally
movable drive member 2226 may include a rack of drive teeth 2224
formed thereon for meshing engagement with the gear reducer
assembly 2222. In certain circumstances, as illustrated in FIG. 50,
the surgical instrument 2200 may include a manually-actuatable
"bailout" assembly 2228 that can be configured to enable a
clinician to manually retract the longitudinally movable drive
member 2226 when a bailout error is detected such as, for example,
when the motor 2216 malfunctions during operation of the surgical
instrument 2200 which may cause tissue captured by the end effector
2208 to be trapped.
[0228] Further to the above, as illustrated in FIG. 50, the bailout
assembly 2228 may include a lever or bailout handle 2230 configured
to be manually moved or pivoted into ratcheting engagement with the
teeth 2224 in the drive member 2226. In such circumstances, the
clinician can manually retract the drive member 2226 by using the
bailout handle 2230 to ratchet the drive member 2226 in the
proximal direction "P", for example, to release the trapped tissue
from the end effector 2208, for example. Exemplary bailout
arrangements and other components, arrangements and systems that
may be employed with the various instruments disclosed herein are
disclosed in U.S. patent application Ser. No. 12/249,117, entitled
POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY
RETRACTABLE FIRING SYSTEM, now U.S. Patent Application Publication
No. 2010/0089970, which is hereby incorporated by reference herein
in its entirety.
[0229] Further to the above, referring now primarily to FIGS. 48
and 50, the bailout handle 2230 of the bailout assembly 2228 may
reside within the housing 2210 of the handle assembly 2202. In
certain circumstances, access to the bailout handle 2230 can be
controlled by a bailout door 2232. The bailout door 2232 can be
releasably locked to the housing 2210 to control access to the
bailout handle 2230. As illustrated in FIG. 48, the bailout door
2232 may include a locking mechanism such as, for example, a
snap-type locking mechanism 2234 for locking engagement with the
housing 2210. Other locking mechanisms for locking the bailout door
2232 to the housing 2210 are contemplated by the present
disclosure. In use, a clinician may obtain access to the bailout
handle 2230 by unlocking the locking mechanism 2234 and opening the
bailout door 2232. In at least one example, the bailout door 2232
can be separably coupled to the housing 2232 and can be detached
from the housing 2210 to provide access to the bailout handle 2230,
for example. In another example, the bailout door 2232 can be
pivotally coupled to the housing 2210 via hinges (not shown) and
can be pivoted relative to the housing 2210 to provide access to
the bailout handle 2230, for example. In yet another example, the
bailout door 2232 can be a sliding door which can be slidably
movable relative to the housing 2210 to provide access to the
bailout handle 2230.
[0230] Referring now to FIG. 51, the surgical instrument 2200 may
include a bailout feedback system 2236 which can be configured to
guide and/or provide feedback to a clinician through the various
steps of utilizing the bailout assembly 2228, as described below in
greater detail. In certain instances, the bailout feedback system
2236 may include a microcontroller 2238 and/or one or more bailout
feedback elements. The electrical and electronic circuit elements
associated with the bailout feedback system 2236 and/or the bailout
feedback elements may be supported by the control circuit board
assembly 2220, for example. The microcontroller 2238 may generally
comprise a memory 2240 and a microprocessor 2242 ("processor")
operationally coupled to the memory 2240. The processor 2242 may
control a motor driver 2244 circuit generally utilized to control
the position and velocity of the motor 2216. In certain instances,
the processor 2242 can signal the motor driver 2244 to stop and/or
disable the motor 2216, as described in greater detail below. In
certain instances, the processor 2242 may control a separate motor
override circuit which may comprise a motor override switch that
can stop and/or disable the motor 2216 during operation of the
surgical instrument 2200 in response to an override signal from the
processor 2242. It should be understood that the term processor as
used herein includes any suitable microprocessor, microcontroller,
or other basic computing device that incorporates the functions of
a computer's central processing unit (CPU) on an integrated circuit
or at most a few integrated circuits. The processor is a
multipurpose, programmable device that accepts digital data as
input, processes it according to instructions stored in its memory,
and provides results as output. It is an example of sequential
digital logic, as it has internal memory. Processors operate on
numbers and symbols represented in the binary numeral system.
[0231] In one instance, the processor 2242 may be any single core
or multicore processor such as those known under the trade name ARM
Cortex by Texas Instruments. In one instance, the surgical
instrument 2200 may comprise a safety processor such as, for
example, a safety microcontroller platform comprising two
microcontroller-based families such as TMS570 and RM4x known under
the trade name Hercules ARM Cortex R4, also by Texas Instruments.
Nevertheless, other suitable substitutes for microcontrollers and
safety processor may be employed, without limitation. In one
instance, the safety processor 1004 may be configured specifically
for IEC 61508 and ISO 26262 safety critical applications, among
others, to provide advanced integrated safety features while
delivering scalable performance, connectivity, and memory
options.
[0232] In certain instances, the microcontroller 2238 may be an LM
4F230H5QR, available from Texas Instruments, for example. In at
least one example, the Texas Instruments LM4F230H5QR is an ARM
Cortex-M4F Processor Core comprising on-chip memory 2240 of 256 KB
single-cycle flash memory, or other non-volatile memory, up to 40
MHz, a prefetch buffer to improve performance above 40 MHz, a 32 KB
single-cycle serial random access memory (SRAM), internal read-only
memory (ROM) loaded with StellarisWare.RTM. software, 2 KB
electrically erasable programmable read-only memory (EEPROM), one
or more pulse width modulation (PWM) modules, one or more
quadrature encoder inputs (QED analog, one or more 12-bit
Analog-to-Digital Converters (ADC) with 12 analog input channels,
among other features that are readily available for the product
datasheet. Other microcontrollers may be readily substituted for
use in the bailout feedback system 2236. Accordingly, the present
disclosure should not be limited in this context.
[0233] Referring again to FIG. 51, the bailout feedback system 2236
may include a bailout door feedback element 2246, for example. In
certain instances, the bailout door feedback element 2246 can be
configured to alert the processor 2242 that the locking mechanism
2234 is unlocked. In at least one example, the bailout door
feedback element 2246 may comprise a switch circuit (not shown)
operably coupled to the processor 2242; the switch circuit can be
configured to be transitioned to an open configuration when the
locking mechanism 2234 is unlocked by a clinician and/or
transitioned to a closed configuration when the locking mechanism
2234 is locked by the clinician, for example. In at least one
example, the bailout door feedback element 2246 may comprise at
least one sensor (not shown) operably coupled to the processor
2242; the sensor can be configured to be triggered when the locking
mechanism 2234 is transitioned to unlocked and/or locked
configurations by the clinician, for example. The reader will
appreciate that the bailout door feedback element 2246 may include
other means for detecting the locking and/or unlocking of the
locking mechanism 2234 by the clinician.
[0234] In certain instances, the bailout door feedback element 2246
may comprise a switch circuit (not shown) operably coupled to the
processor 2242; the switch circuit can be configured to be
transitioned to an open configuration when the bailout door 2232 is
removed or opened, for example, and/or transitioned to a closed
configuration when the bailout door 2232 is installed or closed,
for example. In at least one example, the bailout door feedback
element 2246 may comprise at least one sensor (not shown) operably
coupled to the processor 2242; the sensor can be configured to be
triggered when the bailout door 2232 is removed or opened, for
example, and/or when the bailout door 2232 is closed or installed,
for example. The reader will appreciate that the bailout door
feedback element 2246 may include other means for detecting the
locking and/or unlocking of the locking mechanism 2234 and/or the
opening and/or closing of the bailout door 2232 by the
clinician.
[0235] In certain instances, as illustrated in FIG. 51, the bailout
feedback system 2236 may comprise one or more additional feedback
elements 2248 which may comprise additional switch circuits and/or
sensors in operable communication with the processor 2242; the
additional switch circuits and/or sensors may be employed by the
processor 2242 to measure other parameters associated with the
bailout feedback system 2236. In certain instances, the bailout
feedback system 2236 may comprise one or more interfaces which may
include one or more devices for providing a sensory feedback to a
user. Such devices may comprise, for example, visual feedback
devices such as display screens and/or LED indicators, for example.
In certain instances, such devices may comprise audio feedback
devices such as speakers and/or buzzers, for example. In certain
instances, such devices may comprise tactile feedback devices such
as haptic actuators, for example. In certain instances, such
devices may comprise combinations of visual feedback devices, audio
feedback devices, and/or tactile feedback devices. In certain
circumstances, as illustrated in FIG. 48, the one or more
interfaces may comprise a display 2250 which may be included in the
handle assembly 2202, for example. In certain instances, the
processor 2242 may employ the display 2250 to alert, guide, and/or
provide feedback to a user of the surgical instrument 2200 with
regard to performing a manual bailout of the surgical instrument
2200 using the bailout assembly 2228.
[0236] In certain instances, the bailout feedback system 2236 may
comprise one or more embedded applications implemented as firmware,
software, hardware, or any combination thereof. In certain
instances, the bailout feedback system 2236 may comprise various
executable modules such as software, programs, data, drivers,
and/or application program interfaces (APIs), for example. FIG. 52
depicts an exemplary module 2252 that can be stored in the memory
2240, for example. The module 2252 can be executed by the processor
2242, for example, to alert, guide, and/or provide feedback to a
user of the surgical instrument 2200 with regard to performing a
manual bailout of the surgical instrument 2200 using the bailout
assembly 2228.
[0237] As illustrated in FIG. 52, the module 2252 may be executed
by the processor 2242 to provide the user with instructions as to
how to access and/or use the bailout assembly 2228 to perform the
manual bailout of the surgical instrument 2200, for example. In
various instances, the module 2252 may comprise one or more
decision-making steps such as, for example, a decision-making step
2254 with regard to the detection of one or more errors requiring
the manual bailout of the surgical instrument 2200.
[0238] In various instances, the processor 2242 may be configured
to detect a bailout error in response to the occurrence of one or
more intervening events during the normal operation of the surgical
instrument 2200, for example. In certain instances, the processor
2242 may be configured to detect a bailout error when one or more
bailout error signals are received by the processor 2242; the
bailout error signals can be communicated to the processor 2242 by
other processors and/or sensors of the surgical instrument 2200,
for example. In certain instances, a bailout error can be detected
by the processor 2242 when a temperature of the surgical instrument
2200, as detected by a sensor (not shown), exceeds a threshold, for
example. In certain instances, the surgical instrument 2200 may
comprise a positioning system (not shown) for sensing and recording
the position of the longitudinally-movable drive member 2226 during
a firing stroke of the firing drive system 2214. In at least one
example, the processor 2242 can be configured to detect a bailout
error when one or more of the recorded positions of the
longitudinally-movable drive member 2226 is not are accordance with
a predetermined threshold, for example.
[0239] In any event, referring again to FIG. 52, when the processor
2242 detects a bailout error in the decision-making step 2254, the
processor 2242 may respond by stopping and/or disabling the motor
2216, for example. In addition, in certain instances, the processor
2242 also may store a bailed out state in the memory 2240 after
detecting the bailout error, as illustrated in FIG. 52. In other
words, the processor 2242 may store in the memory 2240 a status
indicating that a bailout error has been detected. As described
above, the memory 2240 can be a non-volatile memory which may
preserve the stored status that a bailout error has been detected
when the surgical instrument 2200 is reset by the user, for
example.
[0240] In various instances, the motor 2216 can be stopped and/or
disabled by disconnecting the battery 2218 from the motor 2216, for
example. In various instances, the processor 2242 may employ the
driver 2244 to stop and/or disable the motor 2216. In certain
instances, when the motor override circuit is utilized, the
processor 2242 may employ the motor override circuit to stop and/or
disable the motor 2216. In certain instances, stopping and/or
disabling the motor 2216 may prevent a user of the surgical
instrument 2200 from using the motor 2216 at least until the manual
bailout is performed, for example. The reader will appreciate that
stopping and/or disabling the motor 2216 in response to the
detection of a bailout error can be advantageous in protecting
tissue captured by the surgical instrument 2200.
[0241] Further to the above, referring still to FIG. 52, the module
2252 may include a decision-making step 2256 for detecting whether
the bailout door 2232 is removed. As described above, the processor
2242 can be operationally coupled to the bailout door feedback
element 2246 which can be configured to alert the processor 2242 as
to whether the bailout door 2232 is removed. In certain instances,
the processor 2242 can be programmed to detect that the bailout
door 2232 is removed when the bailout door feedback element 2246
reports that the locking mechanism 2234 is unlocked, for example.
In certain instances, the processor 2242 can be programmed to
detect that the bailout door 2232 is removed when the bailout door
feedback element 2246 reports that the bailout door 2232 is opened,
for example. In certain instances, the processor 2242 can be
programmed to detect that the bailout door 2232 is removed when the
bailout door feedback element 2246 reports that the locking
mechanism 2234 is unlocked and that the bailout door 2232 is
opened, for example.
[0242] In various instances, referring still to FIG. 52, when the
processor 2242 does not detect a bailout error in the
decision-making step 2254 and does not detect that the bailout door
2232 is removed in the decision-making step 2256, the processor
2242 may not interrupt the normal operation of the surgical
instrument 2200 and may proceed with various clinical algorithms.
In certain instances, when the processor 2242 does not detect a
bailout error in the decision-making step 2254 but detects that the
bailout door 2232 is removed in the decision-making step 2256, the
processor 2242 may respond by stopping and/or disabling the motor
2216, as described above. In addition, in certain instances, the
processor 2242 also may provide the user with instructions to
reinstall the bailout door 2232, as described in greater detail
below. In certain instances, when the processor 2242 detects that
the bailout door 2232 is reinstalled, while no bailout error is
detected, the processor 2242 can be configured to reconnect the
power to the motor 2216 and allow the user to continue with
clinical algorithms, as illustrated in FIG. 52.
[0243] In certain instances, when the user does not reinstall the
bailout door 2232, the processor 2242 may not reconnect power to
the motor 2216 and may continue providing the user with the
instructions to reinstall the bailout door 2232. In certain
instances, when the user does not reinstall the bailout door 2232,
the processor 2242 may provide the user with a warning that the
bailout door 2232 needs to be reinstalled in order to continue with
the normal operation of the surgical instrument 2200. In certain
instances, the surgical instrument 2200 can be equipped with an
override mechanism (not shown) to permit the user to reconnect
power to the motor 2216 even when the bailout door 2216 is not
installed.
[0244] In various instances, the processor 2242 can be configured
to provide the user with a sensory feedback when the processor 2242
detects that the bailout door 2232 is removed. In various
instances, the processor 2242 can be configured to provide the user
with a sensory feedback when the processor 2242 detects that the
bailout door 2232 is reinstalled. Various devices can be employed
by the processor 2242 to provide the sensory feedback to the user.
Such devices may comprise, for example, visual feedback devices
such as display screens and/or LED indicators, for example. In
certain instances, such devices may comprise audio feedback devices
such as speakers and/or buzzers, for example. In certain instances,
such devices may comprise tactile feedback devices such as haptic
actuators, for example. In certain instances, such devices may
comprise combinations of visual feedback devices, audio feedback
devices, and/or tactile feedback devices. In certain instances, the
processor 2242 may employ the display 2250 to instruct the user to
reinstall the bailout door 2232. For example, the processor 2242
may present an alert symbol next to an image of the bailout door
2232 to the user through the display 2250, for example. In certain
instances, the processor 2242 may present an animated image of the
bailout door 2232 being installed, for example. Other images,
symbols, and/or words can be displayed through the display 2250 to
alert the user of the surgical instrument 2200 to reinstall the
bailout door 2232.
[0245] Referring again to FIG. 52, when a bailout error is
detected, the processor 2242 may signal the user of the surgical
instrument 2200 to perform the manual bailout using the bailout
handle 2230. In various instances, the processor 2242 can signal
the user to perform the manual bailout by providing the user with a
visual, audio, and/or tactile feedback, for example. In certain
instances, as illustrated in FIG. 52, the processor 2242 can signal
the user of the surgical instrument 2200 to perform the manual
bailout by flashing a backlight of the display 2250. In any event,
the processor 2242 may then provide the user with instructions to
perform the manual bailout. In various instances, as illustrated in
FIG. 52, the instructions may depend on whether the bailout door
2232 is installed; a decision making step 2258 may determine the
type of instructions provided to the user. In certain instances,
when the processor 2242 detects that the bailout door 2232 is
installed, the processor 2242 may provide the user with
instructions to remove the bailout door 2232 and instructions to
operate the bailout handle 2230, for example. However, when the
processor 2242 detects that the bailout door 2232 is removed, the
processor 2242 may provide the user with the instructions to
operate the bailout handle 2230 but not the instructions to remove
the bailout door 2232, for example.
[0246] Referring again to FIG. 52, in various instances, the
instructions provided by the processor 2242 to the user to remove
the bailout door 2232 and/or to operate the bailout handle 2230 may
comprise one or more steps; the steps may be presented to the user
in a chronological order. In certain instances, the steps may
comprise actions to be performed by the user. In such instances,
the user may proceed through the steps of the manual bailout by
performing the actions presented in each of the steps. In certain
instances, the actions required in one or more of the steps can be
presented to the user in the form of animated images displayed on
the display 2250, for example. In certain instances, one or more of
the steps can be presented to the user as messages which may
include words, symbols, and/or images that guide the user through
the manual bailout. In certain instances, one or more of the steps
of performing the manual bailout can be combined in one or more
messages, for example. In certain instances, each message may
comprise a separate step, for example.
[0247] In certain instances, the steps and/or the messages
providing the instructions for the manual bailout can be presented
to the user in predetermined time intervals to allow the user
sufficient time to comply with the presented steps and/or messages,
for example. In certain instances, the processor 2242 can be
programed to continue presenting a step and/or a message until
feedback is received by the processor 2242 that the step has been
performed. In certain instances, the feedback can be provided to
the processor 2242 by the bailout door feedback element 2246, for
example. Other mechanisms and/or sensors can be employed by the
processor 2242 to obtain feedback that a step has been completed.
In at least one example, the user can be instructed to alert that
processor 2242 when a step is completed by pressing an alert
button, for example. In certain instances, the display 2250 may
comprise a capacitive screen which may provide the user with an
interface to alert the processor 2242 when a step is completed. For
example, the user may press the capacitive screen to move to the
next step of the manual bailout instructions after a current step
is completed.
[0248] In certain instances, as illustrated in FIG. 52, after
detecting that the bailout door 2232 is installed, the processor
2242 can be configured to employ the display 2250 to present an
animated image 2260 depicting a hand moving toward the bailout door
2232. The processor 2242 may continue to display the animated image
2260 for a time interval sufficient for the user to engage the
bailout door 2232, for example. In certain instances, the processor
2242 may then replace the animated image 2260 with an animated
image 2262 depicting a finger engaging the bailout door locking
mechanism 2234, for example. The processor 2242 may continue to
display the animated image 2262 for a time interval sufficient for
the user to unlock the locking mechanism 2234, for example. In
certain instances, the processor 2242 may continue to display the
animated image 2262 until the bailout door feedback element 2246
reports that the locking mechanism 2234 is unlocked, for example.
In certain instances, the processor 2242 may continue to display
the animated image 2262 until the user alerts the processor 2242
that the step of unlocking the locking mechanism 2234 is
completed.
[0249] In any event, the processor 2242 may then replace the
animated image 2262 with an animated image 2264 depicting a finger
removing the bailout door 2232, for example. The processor 2242 may
continue to display the animated image 2264 for a time interval
sufficient for the user to remove the bailout door 2232, for
example. In certain instances, the processor 2242 may continue to
display the animated image 2264 until the bailout door feedback
element 2246 reports that the bailout door 2232 is removed, for
example. In certain instances, the processor 2242 may continue to
display the animated image 2264 until the user alerts the processor
2242 that the step of removing the bailout door 2232 has been
removed, for example. In certain instances, the processor 2242 can
be configured to continue to repeat displaying the animated images
2260, 2262, and 2246 in their respective order when the processor
2242 continues to detect that the bailout door is installed at the
decision making step 2258, for example.
[0250] Further to the above, after detecting that the bailout door
2232 is removed, the processor 2242 may proceed to guide the user
through the steps of operating the bailout handle 2230. In certain
instances, the processor 2242 may replace the animated image 2264
with an animated image 2266 depicting a finger lifting the bailout
handle 2230, for example, into ratcheting engagement with the teeth
2224 in the drive member 2226, as described above. The processor
2242 may continue to display the animated image 2266 for a time
interval sufficient for the user to lift the bailout handle 2230,
for example. In certain instances, the processor 2242 may continue
to display the animated image 2266 until the processor receives
feedback that the bailout handle 2230 has been lifted. For example,
the processor 2242 may continue to display the animated image 2266
until the user alerts the processor 2242 that the step of lifting
the bailout handle 2230 has been removed.
[0251] In certain instances, as described above, the user can
manually retract the drive member 2226 by using the bailout handle
2230 to ratchet the drive member 2226 in the proximal direction
"P," for example, to release tissue trapped by the end effector
2208, for example. In such instances, the processor 2242 may
replace the animated image 2266 with an animated image 2268
depicting a finger repeatedly pulling then pushing the bailout
handle 2230, for example, to simulate the ratcheting of the bailout
handle 2230. The processor 2242 may continue to display the
animated image 2268 for a time interval sufficient for the user to
ratchet the drive member 2226 to default position, for example. In
certain instances, the processor 2242 may continue to display the
animated image 2268 until the processor 2242 receives feedback that
the drive member 2226 has been retracted.
[0252] FIG. 53 depicts a module 2270 which is similar in many
respects to the module 2258. For example, the module 2252 also can
be stored in the memory 2240 and/or executed by the processor 2242,
for example, to alert, guide, and/or provide feedback to a user of
the surgical instrument 2200 with regard to performing a manual
bailout of the surgical instrument 2200. In certain instances, the
surgical instrument 2200 may not comprise a bailout door. In such
circumstances, the module 2270 can be employed by the processor
2242 to provide the user with instructions as to how to operate the
bailout handle 2230, for example.
[0253] Referring again to the module 2270 depicted in FIG. 53, when
the processor 2242 does not detect a bailout error in the
decision-making step 2254 of the module 2270, the processor 2242
may not interrupt the normal operation of the surgical instrument
2200 and may proceed with various clinical algorithms. However,
when the processor 2242 detects a bailout error in the
decision-making step 2254 of the module 2270, the processor 2242
may respond by stopping and/or disabling the motor 2216, for
example. In addition, in certain instances, the processor 2242 also
may store a bailed out state in the memory 2240 after detecting the
bailout error, as illustrated in FIG. 53. In the absence of a
bailout door, the processor 2242 may signal the user of the
surgical instrument 2200 to perform the manual bailout, for
example, by flashing the backlight of the display 2250; the
processor 2242 may then proceed directly to providing the user with
the instructions to operate the bailout handle 2230, as described
above.
[0254] The reader will appreciate that the steps depicted in FIGS.
52 and/or 53 are illustrative examples of the instructions that can
be provided to the user of the surgical instrument 2200 to perform
a manual bailout. The modules 2252 and/or 2270 can be configured to
provide more or less steps than those illustrated in FIGS. 52 and
53. The reader will also appreciate that the modules 2252 and/or
2270 are exemplary modules; various other modules can be executed
by the processor 2242 to provide the user of the surgical
instrument 2200 with instructions to perform the manual
bailout.
[0255] In various instances, as described above, the processor 2242
can be configured to present to the user of the surgical instrument
2200 the steps and/or messages for performing a manual bailout in
predetermined time intervals. Such time intervals may be the same
or may vary depending on the complexity of the task to be performed
by the user, for example. In certain instances, such time intervals
can be any time interval in the range of about 1 second, for
example, to about 10 minutes, for example. In certain instances,
such time intervals can be any time interval in the range of about
1 second, for example, to about 1 minute, for example. Other time
intervals are contemplated by the present disclosure.
[0256] In some instances, a power assembly, such as, for example
the power assembly 2006 illustrated in FIGS. 31-33B, is configured
to monitor the number of uses of the power assembly 2006 and/or a
surgical instrument 2000 coupled to the power assembly 2006. The
power assembly 2006 maintains a usage cycle count corresponding to
the number of uses. The power assembly 2006 and/or the surgical
instrument 2000 performs one or more actions based on the usage
cycle count. For example, in some instances, when the usage cycle
count exceeds a predetermined usage limit, the power assembly 2006
and/or a surgical instrument 2000 may disable the power assembly
2006, disable the surgical instrument 2000, indicate that a
reconditioning or service cycle is required, provide a usage cycle
count to an operator and/or a remote system, and/or perform any
other suitable action. The usage cycle count is determined by any
suitable system, such as, for example, a mechanical limiter, a
usage cycle circuit, and/or any other suitable system coupled to
the battery 2006 and/or the surgical instrument 2000.
[0257] FIG. 54 illustrates one example of a power assembly 2400
comprising a usage cycle circuit 2402 configured to monitor a usage
cycle count of the power assembly 2400. The power assembly 2400 may
be coupled to a surgical instrument 2410. The usage cycle circuit
2402 comprises a processor 2404 and a use indicator 2406. The use
indicator 2406 is configured to provide a signal to the processor
2404 to indicate a use of the battery back 2400 and/or a surgical
instrument 2410 coupled to the power assembly 2400. A "use" may
comprise any suitable action, condition, and/or parameter such as,
for example, changing a modular component of a surgical instrument
2410, deploying or firing a disposable component coupled to the
surgical instrument 2410, delivering electrosurgical energy from
the surgical instrument 2410, reconditioning the surgical
instrument 2410 and/or the power assembly 2400, exchanging the
power assembly 2400, recharging the power assembly 2400, and/or
exceeding a safety limitation of the surgical instrument 2410
and/or the battery back 2400.
[0258] In some instances, a usage cycle, or use, is defined by one
or more power assembly 2400 parameters. For example, in one
instance, a usage cycle comprises using more than 5% of the total
energy available from the power assembly 2400 when the power
assembly 2400 is at a full charge level. In another instance, a
usage cycle comprises a continuous energy drain from the power
assembly 2400 exceeding a predetermined time limit. For example, a
usage cycle may correspond to five minutes of continuous and/or
total energy draw from the power assembly 2400. In some instances,
the power assembly 2400 comprises a usage cycle circuit 2402 having
a continuous power draw to maintain one or more components of the
usage cycle circuit 2402, such as, for example, the use indicator
2406 and/or a counter 2408, in an active state.
[0259] The processor 2404 maintains a usage cycle count. The usage
cycle count indicates the number of uses detected by the use
indicator 2406 for the power assembly 2400 and/or the surgical
instrument 2410. The processor 2404 may increment and/or decrement
the usage cycle count based on input from the use indicator 2406.
The usage cycle count is used to control one or more operations of
the power assembly 2400 and/or the surgical instrument 2410. For
example, in some instances, a power assembly 2400 is disabled when
the usage cycle count exceeds a predetermined usage limit. Although
the instances discussed herein are discussed with respect to
incrementing the usage cycle count above a predetermined usage
limit, those skilled in the art will recognize that the usage cycle
count may start at a predetermined amount and may be decremented by
the processor 2404. In this instance, the processor 2404 initiates
and/or prevents one or more operations of the power assembly 2400
when the usage cycle count falls below a predetermined usage
limit.
[0260] The usage cycle count is maintained by a counter 2408. The
counter 2408 comprises any suitable circuit, such as, for example,
a memory module, an analog counter, and/or any circuit configured
to maintain a usage cycle count. In some instances, the counter
2408 is formed integrally with the processor 2404. In other
instances, the counter 2408 comprises a separate component, such
as, for example, a solid state memory module. In some instances,
the usage cycle count is provided to a remote system, such as, for
example, a central database. The usage cycle count is transmitted
by a communications module 2412 to the remote system. The
communications module 2412 is configured to use any suitable
communications medium, such as, for example, wired and/or wireless
communication. In some instances, the communications module 2412 is
configured to receive one or more instructions from the remote
system, such as, for example, a control signal when the usage cycle
count exceeds the predetermined usage limit.
[0261] In some instances, the use indicator 2406 is configured to
monitor the number of modular components used with a surgical
instrument 2410 coupled to the power assembly 2400. A modular
component may comprise, for example, a modular shaft, a modular end
effector, and/or any other modular component. In some instances,
the use indicator 2406 monitors the use of one or more disposable
components, such as, for example, insertion and/or deployment of a
staple cartridge within an end effector coupled to the surgical
instrument 2410. The use indicator 2406 comprises one or more
sensors for detecting the exchange of one or more modular and/or
disposable components of the surgical instrument 2410.
[0262] In some instances, the use indicator 2406 is configured to
monitor single patient surgical procedures performed while the
power assembly 2400 is installed. For example, the use indicator
2406 may be configured to monitor firings of the surgical
instrument 2410 while the power assembly 2400 is coupled to the
surgical instrument 2410. A firing may correspond to deployment of
a staple cartridge, application of electrosurgical energy, and/or
any other suitable surgical event. The use indicator 2406 may
comprise one or more circuits for measuring the number of firings
while the power assembly 2400 is installed. The use indicator 2406
provides a signal to the processor 2404 when a single patient
procedure is performed and the processor 2404 increments the usage
cycle count.
[0263] In some instances, the use indicator 2406 comprises a
circuit configured to monitor one or more parameters of the power
source 2414, such as, for example, a current draw from the power
source 2414. The one or more parameters of the power source 2414
correspond to one or more operations performable by the surgical
instrument 2410, such as, for example, a cutting and sealing
operation. The use indicator 2406 provides the one or more
parameters to the processor 2404, which increments the usage cycle
count when the one or more parameters indicate that a procedure has
been performed.
[0264] In some instances, the use indicator 2406 comprises a timing
circuit configured to increment a usage cycle count after a
predetermined time period. The predetermined time period
corresponds to a single patient procedure time, which is the time
required for an operator to perform a procedure, such as, for
example, a cutting and sealing procedure. When the power assembly
2400 is coupled to the surgical instrument 2410, the processor 2404
polls the use indicator 2406 to determine when the single patient
procedure time has expired. When the predetermined time period has
elapsed, the processor 2404 increments the usage cycle count. After
incrementing the usage cycle count, the processor 2404 resets the
timing circuit of the use indicator 2406.
[0265] In some instances, the use indicator 2406 comprises a time
constant that approximates the single patient procedure time. FIG.
55 illustrates one instance of power assembly 2500 comprising a
usage cycle circuit 2502 having a resistor-capacitor (RC) timing
circuit 2506. The RC timing circuit 2506 comprises a time constant
defined by a resistor-capacitor pair. The time constant is defined
by the values of the resistor 2516 and the capacitor 2518 When the
power assembly 2500 is installed in a surgical instrument, a
processor 2504 polls the RC timing circuit 2506. When one or more
parameters of the RC timing circuit 2506 are below a predetermined
threshold, the processor 2504 increments the usage cycle count. For
example, the processor 2504 may poll the voltage of the capacitor
2518 of the resistor-capacitor pair 2506. When the voltage of the
capacitor 2518 is below a predetermined threshold, the processor
2504 increment the usage cycle count. The processor 2504 may be
coupled to the RC timing circuit 2506 by, for example, an A/D 2520.
After incrementing the usage cycle count, the processor 2504 turns
on a transistor 2522 to connect the RC timing circuit 2506 to a
power source 2514 to charge the capacitor 2518 of the RC timing
circuit 2506. Once the capacitor 2518 is fully charged, the
transistor 2522 is opened and the RC timing circuit 2506 is allowed
to discharge, as governed by the time constant, to indicate a
subsequent single patient procedure.
[0266] FIG. 56 illustrates one instance of a power assembly 2550
comprising a usage cycle circuit 2552 having a rechargeable battery
2564 and a clock 2560. When the power assembly 2550 is installed in
a surgical instrument, the rechargeable battery 2564 is charged by
the power source 2558. The rechargeable battery 2564 comprises
enough power to run the clock 2560 for at least the single patient
procedure time. The clock 2560 may comprise a real time clock, a
processor configured to implement a time function, or any other
suitable timing circuit. The processor 2554 receives a signal from
the clock 2560 and increments the usage cycle count when the clock
2560 indicates that the single patient procedure time has been
exceeded. The processor 2554 resets the clock 2560 after
incrementing the usage cycle count. For example, in one instance,
the processor 2554 closes a transistor 2562 to recharge the
rechargeable battery 2564. Once the rechargeable battery 2564 is
fully charged, the processor 2554 opens the transistor 2562, and
allows the clock 2560 to run while the rechargeable battery 2564
discharges.
[0267] Referring back to FIG. 54, in some instances, the use
indicator 2406 comprises a sensor configured to monitor one or more
environmental conditions experienced by the power assembly 2400.
For example, the use indicator 2406 may comprise an accelerometer.
The accelerometer is configured to monitor acceleration of the
power assembly 2400. The power assembly 2400 comprises a maximum
acceleration tolerance. Acceleration above a predetermined
threshold indicates, for example, that the power assembly 2400 has
been dropped. When the use indicator 2406 detects acceleration
above the maximum acceleration tolerance, the processor 2404
increments a usage cycle count. In some instances, the use
indicator 2406 comprises a moisture sensor. The moisture sensor is
configured to indicate when the power assembly 2400 has been
exposed to moisture. The moisture sensor may comprise, for example,
an immersion sensor configured to indicate when the power assembly
2400 has been fully immersed in a cleaning fluid, a moisture sensor
configured to indicate when moisture is in contact with the power
assembly 2400 during use, and/or any other suitable moisture
sensor.
[0268] In some instances, the use indicator 2406 comprises a
chemical exposure sensor. The chemical exposure sensor is
configured to indicate when the power assembly 2400 has come into
contact with harmful and/or dangerous chemicals. For example,
during a sterilization procedure, an inappropriate chemical may be
used that leads to degradation of the power assembly 2400. The
processor 2404 increments the usage cycle count when the use
indicator 2406 detects an inappropriate chemical.
[0269] In some instances, the usage cycle circuit 2402 is
configured to monitor the number of reconditioning cycles
experienced by the power assembly 2400. A reconditioning cycle may
comprise, for example, a cleaning cycle, a sterilization cycle, a
charging cycle, routine and/or preventative maintenance, and/or any
other suitable reconditioning cycle. The use indicator 2406 is
configured to detect a reconditioning cycle. For example, the use
indicator 2406 may comprise a moisture sensor to detect a cleaning
and/or sterilization cycle. In some instances, the usage cycle
circuit 2402 monitors the number of reconditioning cycles
experienced by the power assembly 2400 and disables the power
assembly 2400 after the number of reconditioning cycles exceeds a
predetermined threshold.
[0270] The usage cycle circuit 2402 may be configured to monitor
the number of power assembly 2400 exchanges. The usage cycle
circuit 2402 increments the usage cycle count each time the power
assembly 2400 is exchanged. When the maximum number of exchanges is
exceeded, the usage cycle circuit 2402 locks out the power assembly
2400 and/or the surgical instrument 2410. In some instances, when
the power assembly 2400 is coupled the surgical instrument 2410,
the usage cycle circuit 2402 identifies the serial number of the
power assembly 2400 and locks the power assembly 2400 such that the
power assembly 2400 is usable only with the surgical instrument
2410. In some instances, the usage cycle circuit 2402 increments
the usage cycle each time the power assembly 2400 is removed from
and/or coupled to the surgical instrument 2410.
[0271] In some instances, the usage cycle count corresponds to
sterilization of the power assembly 2400. The use indicator 2406
comprises a sensor configured to detect one or more parameters of a
sterilization cycle, such as, for example, a temperature parameter,
a chemical parameter, a moisture parameter, and/or any other
suitable parameter. The processor 2404 increments the usage cycle
count when a sterilization parameter is detected. The usage cycle
circuit 2402 disables the power assembly 2400 after a predetermined
number of sterilizations. In some instances, the usage cycle
circuit 2402 is reset during a sterilization cycle, a voltage
sensor to detect a recharge cycle, and/or any suitable sensor. The
processor 2404 increments the usage cycle count when a
reconditioning cycle is detected. The usage cycle circuit 2402 is
disabled when a sterilization cycle is detected. The usage cycle
circuit 2402 is reactivated and/or reset when the power assembly
2400 is coupled to the surgical instrument 2410. In some instances,
the use indicator comprises a zero power indicator. The zero power
indicator changes state during a sterilization cycle and is checked
by the processor 2404 when the power assembly 2400 is coupled to a
surgical instrument 2410. When the zero power indicator indicates
that a sterilization cycle has occurred, the processor 2404
increments the usage cycle count.
[0272] A counter 2408 maintains the usage cycle count. In some
instances, the counter 2408 comprises a non-volatile memory module.
The processor 2404 increments the usage cycle count stored in the
non-volatile memory module each time a usage cycle is detected. The
memory module may be accessed by the processor 2404 and/or a
control circuit, such as, for example, the control circuit 1100.
When the usage cycle count exceeds a predetermined threshold, the
processor 2404 disables the power assembly 2400. In some instances,
the usage cycle count is maintained by a plurality of circuit
components. For example, in one instance, the counter 2408
comprises a resistor (or fuse) pack. After each use of the power
assembly 2400, a resistor (or fuse) is burned to an open position,
changing the resistance of the resistor pack. The power assembly
2400 and/or the surgical instrument 2410 reads the remaining
resistance. When the last resistor of the resistor pack is burned
out, the resistor pack has a predetermined resistance, such as, for
example, an infinite resistance corresponding to an open circuit,
which indicates that the power assembly 2400 has reached its usage
limit. In some instances, the resistance of the resistor pack is
used to derive the number of uses remaining.
[0273] In some instances, the usage cycle circuit 2402 prevents
further use of the power assembly 2400 and/or the surgical
instrument 2410 when the usage cycle count exceeds a predetermined
usage limit. In one instance, the usage cycle count associated with
the power assembly 2400 is provided to an operator, for example,
utilizing a screen formed integrally with the surgical instrument
2410. The surgical instrument 2410 provides an indication to the
operator that the usage cycle count has exceeded a predetermined
limit for the power assembly 2400, and prevents further operation
of the surgical instrument 2410.
[0274] In some instances, the usage cycle circuit 2402 is
configured to physically prevent operation when the predetermined
usage limit is reached. For example, the power assembly 2400 may
comprise a shield configured to deploy over contacts of the power
assembly 2400 when the usage cycle count exceeds the predetermined
usage limit. The shield prevents recharge and use of the power
assembly 2400 by covering the electrical connections of the power
assembly 2400.
[0275] In some instances, the usage cycle circuit 2402 is located
at least partially within the surgical instrument 2410 and is
configured to maintain a usage cycle count for the surgical
instrument 2410. FIG. 54 illustrates one or more components of the
usage cycle circuit 2402 within the surgical instrument 2410 in
phantom, illustrating the alternative positioning of the usage
cycle circuit 2402. When a predetermined usage limit of the
surgical instrument 2410 is exceeded, the usage cycle circuit 2402
disables and/or prevents operation of the surgical instrument 2410.
The usage cycle count is incremented by the usage cycle circuit
2402 when the use indicator 2406 detects a specific event and/or
requirement, such as, for example, firing of the surgical
instrument 2410, a predetermined time period corresponding to a
single patient procedure time, based on one or more motor
parameters of the surgical instrument 2410, in response to a system
diagnostic indicating that one or more predetermined thresholds are
met, and/or any other suitable requirement. As discussed above, in
some instances, the use indicator 2406 comprises a timing circuit
corresponding to a single patient procedure time. In other
instances, the use indicator 2406 comprises one or more sensors
configured to detect a specific event and/or condition of the
surgical instrument 2410.
[0276] In some instances, the usage cycle circuit 2402 is
configured to prevent operation of the surgical instrument 2410
after the predetermined usage limit is reached. In some instances,
the surgical instrument 2410 comprises a visible indicator to
indicate when the predetermined usage limit has been reached and/or
exceeded. For example, a flag, such as a red flag, may pop-up from
the surgical instrument 2410, such as from the handle, to provide a
visual indication to the operator that the surgical instrument 2410
has exceeded the predetermined usage limit. As another example, the
usage cycle circuit 2402 may be coupled to a display formed
integrally with the surgical instrument 2410. The usage cycle
circuit 2402 displays a message indicating that the predetermined
usage limit has been exceeded. The surgical instrument 2410 may
provide an audible indication to the operator that the
predetermined usage limit has been exceeded. For example, in one
instance, the surgical instrument 2410 emits an audible tone when
the predetermined usage limit is exceeded and the power assembly
2400 is removed from the surgical instrument 2410. The audible tone
indicates the last use of the surgical instrument 2410 and
indicates that the surgical instrument 2410 should be disposed or
reconditioned.
[0277] In some instances, the usage cycle circuit 2402 is
configured to transmit the usage cycle count of the surgical
instrument 2410 to a remote location, such as, for example, a
central database. The usage cycle circuit 2402 comprises a
communications module 2412 configured to transmit the usage cycle
count to the remote location. The communications module 2412 may
utilize any suitable communications system, such as, for example,
wired or wireless communications system. The remote location may
comprise a central database configured to maintain usage
information. In some instances, when the power assembly 2400 is
coupled to the surgical instrument 2410, the power assembly 2400
records a serial number of the surgical instrument 2410. The serial
number is transmitted to the central database, for example, when
the power assembly 2400 is coupled to a charger. In some instances,
the central database maintains a count corresponding to each use of
the surgical instrument 2410. For example, a bar code associated
with the surgical instrument 2410 may be scanned each time the
surgical instrument 2410 is used. When the use count exceeds a
predetermined usage limit, the central database provides a signal
to the surgical instrument 2410 indicating that the surgical
instrument 2410 should be discarded.
[0278] The surgical instrument 2410 may be configured to lock
and/or prevent operation of the surgical instrument 2410 when the
usage cycle count exceeds a predetermined usage limit. In some
instances, the surgical instrument 2410 comprises a disposable
instrument and is discarded after the usage cycle count exceeds the
predetermined usage limit. In other instances, the surgical
instrument 2410 comprises a reusable surgical instrument which may
be reconditioned after the usage cycle count exceeds the
predetermined usage limit. The surgical instrument 2410 initiates a
reversible lockout after the predetermined usage limit is met. A
technician reconditions the surgical instrument 2410 and releases
the lockout, for example, utilizing a specialized technician key
configured to reset the usage cycle circuit 2402.
[0279] In some instances, the power assembly 2400 is charged and
sterilized simultaneously prior to use. FIG. 57 illustrates one
instance of a combined sterilization and charging system 2600
configured to charge and sterilize a battery 2602 simultaneously.
The combined sterilization and charging system 2600 comprises a
sterilization chamber 2604. A battery 2602 is placed within the
sterilization chamber 2604. In some instances, the battery 2602 is
coupled to a surgical instrument. A charging cable 2606 is mounted
through a wall 2608 of the sterilization chamber 2604. The wall
2608 is sealed around the charging cable 2606 to maintain a sterile
environment within the sterilization chamber 2604 during
sterilization. The charging cable 2606 comprises a first end
configured to couple to the power assembly 2602 within the
sterilization chamber 2604 and a second end coupled to a battery
charger 2610 located outside of the sterilization chamber 2604.
Because the charging cable 2606 passes through the wall 2608 of the
sterilization chamber 2604 while maintaining a sterile environment
within the sterilization chamber 2604, the power assembly 2602 may
be charged and sterilized simultaneously.
[0280] The charging profile applied by the battery charger 2610 is
configured to match the sterilization cycle of the sterilization
chamber 2604. For example, in one instance, a sterilization
procedure time is about 28 to 38 minutes. The battery charger 2610
is configured to provide a charging profile that charges the
battery during the sterilization procedure time. In some instances,
the charging profile may extend over a cooling-off period following
the sterilization procedure. The charging profile may be adjusted
by the battery charger 2610 based on feedback from the power
assembly 2602 and/or the sterilization chamber 2604. For example,
in one instance, a sensor 2612 is located within the sterilization
chamber 2604. The sensor 2612 is configured to monitor one or more
characteristics of the sterilization chamber 2604, such as, for
example, chemicals present in the sterilization chamber 2604,
temperature of the sterilization chamber 2604, and/or any other
suitable characteristic of the sterilization chamber 2604. The
sensor 2612 is coupled to the battery charger 2610 by a cable 2614
extending through the wall 2608 of the sterilization chamber 2604.
The cable 2614 is sealed such that the sterilization chamber 2604
may maintain a sterile environment. The battery charger 2610
adjusts the charging profile based on feedback from the sensor
2614. For example, in one instance, the battery charger 2610
receives temperature data from the sensor 2612 and adjusts the
charging profile when the temperature of the sterilization chamber
2604 and/or the power assembly 2602 exceeds a predetermined
temperature. As another example, the battery charger 2610 receives
chemical composition information from the sensor 2612 and prevents
charging of the power assembly 2602 when a chemical, such as, for
example, H.sub.2O.sub.2, approaches explosive limits.
[0281] FIG. 58 illustrates one instance of a combination
sterilization and charging system 2650 configured for a power
assembly 2652 having a battery charger 2660 formed integrally
therewith. An alternating current (AC) source 2666 is located
outside of the sterilization chamber 2654 and is coupled the
battery charger 2660 by an AC cable 2656 mounted through a wall
2658 of the sterilization chamber 2654. The wall 2658 is sealed
around the AC cable 2656. The battery charger 2660 operates similar
to the battery charger 2610 illustrated in FIG. 57. In some
instances, the battery charger 2660 receives feedback from a sensor
2662 located within the sterilization chamber 2654 and coupled to
the battery charger 2660 by a cable 2664.
[0282] In various instances, a surgical system can include a magnet
and a sensor. In combination, the magnet and the sensor can
cooperate to detect various conditions of a fastener cartridge,
such as the presence of a fastener cartridge in an end effector of
the surgical instrument, the type of fastener cartridge loaded in
the end effector, and/or the firing state of a loaded fastener
cartridge, for example. Referring now to FIG. 62, a jaw 902 of an
end effector 900 can comprise a magnet 910, for example, and a
fastener cartridge 920 can comprise a sensor 930, for example. In
various instances, the magnet 910 can be positioned at the distal
end 906 of an elongate channel 904 sized and configured to receive
the fastener cartridge 920. Furthermore, the sensor 930 can be at
least partially embedded or retained in the distal end 926 of the
nose 924 of the fastener cartridge 920, for example. In various
instances, the sensor 924 can be in signal communication with the
microcontroller of the surgical instrument.
[0283] In various circumstances, the sensor 930 can detect the
presence of the magnet 910 when the fastener cartridge 920 is
positioned in the elongate channel 904 of the jaw 902. The sensor
930 can detect when the fastener cartridge 920 is improperly
positioned in the elongate channel 904 and/or not loaded into the
elongate channel 904, for example, and can communicate the
cartridge loading state to the microcontroller of the surgical
system, for example. In certain instances, the magnet 910 can be
positioned in the fastener cartridge 920, for example, and the
sensor 930 can be positioned in the end effector 900, for example.
In various instances, the sensor 930 can detect the type of
fastener cartridge 920 loaded in the end effector 900. For example,
different types of fastener cartridges can have different magnetic
arrangements, such as different placement(s) relative to the
cartridge body or other cartridge components, different polarities,
and/or different magnetic strengths, for example. In such
instances, the sensor 930 can detect the type of cartridge, e.g.,
the cartridge length, the number of fasteners and/or the fastener
height(s), positioned in the jaw 902 based on the detected magnetic
signal. Additionally or alternatively, the sensor 930 can detect if
the fastener cartridge 920 is properly seated in the end effector
900. For example, the end effector 900 and the fastener cartridge
920 can comprise a plurality of magnets and/or a plurality of
sensors and, in certain instances, the sensor(s) can detect whether
the fastener cartridge 920 is properly positioned and/or aligned
based on the position of multiple magnets relative to the
sensor(s), for example.
[0284] Referring now to FIG. 63, in certain instances, an end
effector 3000 can include a plurality of magnets and a plurality of
sensors. For example, a jaw 3002 can include a plurality of magnets
3010, 3012 positioned at the distal end 3006 thereof. Moreover, the
fastener cartridge 3020 can include a plurality of sensors 3030,
3032 positioned at the distal end 3026 of the nose 3024, for
example. In certain instances, the sensors 3030, 3032 can detect
the presence of the fastener cartridge 3020 in the elongate channel
3004 of the jaw 3002. In various instances, the sensors 3030, 3032
can comprise Hall Effect sensors, for example. Various sensors are
described in U.S. Pat. No. 8,210,411, filed Sep. 23, 2008, and
entitled MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT. U.S. Pat. No.
8,210,411, filed Sep. 23, 2008, and entitled MOTOR-DRIVEN SURGICAL
CUTTING INSTRUMENT, is hereby incorporated by reference in its
entirety. The addition of an additional sensor or sensors can
provide a greater bandwidth signal, for example, which can provide
further and/or improved information to the microcontroller of the
surgical instrument. Additionally or alternatively, additional
sensors can determine if the fastener cartridge 3020 is properly
seated in the elongate channel of the jaw 3002, for example.
[0285] In various instances, a magnet can be positioned on a
moveable component of a fastener cartridge. For example, a magnet
can be positioned on a component of the fastener cartridge that
moves during a firing stroke. In such instances, a sensor in the
end effector can detect the firing state of the fastener cartridge.
For example, referring now to FIG. 64, a magnet 3130 can be
positioned on the sled 3122 of a fastener cartridge 3120. Moreover,
a sensor 1110 can be positioned in the jaw 3102 of the end effector
3100. In various circumstances, the sled 3122 can translate during
a firing stroke. Moreover, in certain instances, the sled 3120 can
remain at the distal end of the fastener cartridge 3120 after the
firing stroke. Stated differently, after the cartridge has been
fired, the sled 3120 can remain at the distal end of the fastener
cartridge 3120. Accordingly, the sensor 3110 can detect the
position of the magnet 3130 and the corresponding sled 3120 to
determine the firing state of the fastener cartridge 3120. For
example, when the sensor 3110 detects the proximal position of the
magnet 3130, the fastener cartridge 3120 can be unfired and ready
to fire, for example, and when the sensor 3110 detects the distal
position of the magnet 3130, the fastener cartridge 3120 can be
spent, for example. Referring now to FIG. 65, in various instances,
a jaw 3202 of an end effector 3200 can include a plurality of
sensors 3210, 3212. For example, a proximal sensor 3212 can be
positioned in the proximal portion of the jaw 3202, and a distal
sensor 3210 can be positioned in the distal portion of the jaw
3202, for example. In such instances, the sensors 3210, 3212 can
detect the position of the sled 3122 as the sled 3122 moves during
a firing stroke, for example. In various instances, the sensors
3210, 3212 can comprise Hall Effect sensors, for example.
[0286] Additionally or alternatively, an end effector can include a
plurality of electrical contacts, which can detect the presence
and/or firing state of a fastener cartridge. Referring now to FIG.
66, an end effector 3300 can include a jaw 3302 defining a channel
3304 configured to receive a fastener cartridge 3320. In various
instances, the jaw 3302 and the fastener cartridge 3320 can
comprise electrical contacts. For example, the elongate channel
3304 can define a bottom surface 3306, and an electrical contact
3310 can be positioned on the bottom surface 3306. In various
instances, a plurality of electrical contacts 3310 can be defined
in the elongate channel 3304. The electrical contacts 3310 can form
part of a firing-state circuit 3340, which can be in signal
communication with a microcontroller of the surgical system. For
example, the electrical contacts 3310 can be electrically coupled
to and/or in communication with a power supply, and can form
electrically active ends of an open circuit, for example. In some
instances, one of the electrical contacts 3310 can be powered such
that a voltage potential is created intermediate the electrical
contacts 3310. In certain instances, one of the contacts can be
coupled to an output channel of the microprocessor, for example,
which can apply a voltage potential to the contact. Another contact
can be coupled to an input channel of the microprocessor, for
example. In certain instances, the electrical contacts 3310 can be
insulated from the frame 3306 of the jaw 3302. Referring still to
FIG. 66, the fastener cartridge 3320 can also include an electrical
contact 3330, or a plurality of electrical contacts, for example.
In various instances, the electrical contact 3330 can be positioned
on a moveable element of the fastener cartridge 3320. For example,
the electrical contact 3330 can be positioned on the sled 3322 of
the fastener cartridge 3320, and thus, the electrical contact 3330
can move in the fastener cartridge 3320 during a firing stroke.
[0287] In various instances, the electrical contact 3330 can
comprise a metallic bar or plate on the sled 3320, for example. The
electrical contact 3330 in the fastener cartridge 3320 can
cooperate with the electrical contact(s) 3310 in the end effector
3300, for example. In certain circumstances, the electrical contact
3330 can contact the electrical contact(s) 3310 when the sled 3322
is positioned in a particular position, or a range of positions, in
the fastener cartridge 3320. For example, the electrical contact
3330 can contact the electrical contacts 3310 when the sled 3322 is
unfired, and thus, positioned in a proximal position in the
fastener cartridge 3320. In such circumstances, the electrical
contact 3330 can close the circuit between the electrical contacts
3310, for example. Moreover, the firing-state circuit 3340 can
communicate the closed circuit, i.e., the unfired cartridge
indication, to the microcontroller of the surgical system. In such
instances, when the sled 3322 is fired distally during a firing
stroke, the electrical contact 3330 can move out of electrically
contact with the electrical contacts 3310, for example.
Accordingly, the firing-state circuit 3340 can communicate the open
circuit, i.e., the fired cartridge indication, to the
microcontroller of the surgical system. In certain circumstances,
the microcontroller may only initiate a firing stroke when an
unspent cartridge is indicated by the firing-state circuit 3340,
for example. In various instances, the electrical contact 3330 can
comprise an electromechanical fuse. In such instances, the fuse can
break or short when the sled 3322 is fired through a firing stroke,
for example.
[0288] Additionally or alternatively, referring now to FIG. 67, an
end effector 3400 can include a jaw 3402 and a cartridge-present
circuit 3440. In various instances, the jaw 3402 can comprise an
electrical contact 3410, or a plurality of electrical contacts
3410, in an elongate channel 3404 thereof, for example.
Furthermore, a fastener cartridge 3420 can include an electrical
contact 3430, or a plurality of electrical contacts 3430, on an
outer surface of the fastener cartridge 3420. In various instances,
the electrical contacts 3430 can be positioned and/or mounted to a
fixed or stationary component of the fastener cartridge 3420, for
example. In various circumstances, the electrical contacts 3430 of
the fastener cartridge 3420 can contact the electrical contacts
3410 of the end effector 3400 when the fastener cartridge 3420 is
loaded into the elongate channel 3404, for example. Prior to
placement of the fastener cartridge 3420 in the elongate channel
3404, the cartridge-present circuit 3440 can be an open circuit,
for example. When the fastener cartridge 3420 is properly seated in
the jaw 3402, the electrical contacts 3410 and 3430 can form the
closed cartridge-present circuit 3440. In instances where the jaw
3402 and/or the fastener cartridge 3420 comprise a plurality of
electrical contacts 3410, 3430, the cartridge-present circuit 3440
can comprise a plurality of circuits. Moreover, in certain
instances, the cartridge-present circuit 3440 can identify the type
of cartridge loaded in the jaw 3402 based on the number and/or
arrangement of electrical contacts 3430 on the fastener cartridge
3420, for example, and the corresponding open and/or closed
circuits of the cartridge-present circuit 3440, for example.
[0289] Moreover, the electrical contacts 3410 in the jaw 3402 can
be in signal communication with the microcontroller of the surgical
system. The electrical contacts 3410 can be wired to a power
source, for example, and/or can communicate with the
microcontroller via a wired and/or wireless connection, for
example. In various instances, the cartridge-present circuit 3440
can communicate the cartridge presence or absence to the
microcontroller of the surgical system. In various instances, a
firing stroke may be prevented when the cartridge-present circuit
3440 indicates the absence of a fastener cartridge in the end
effector jaw 3402, for example. Moreover, a firing stroke may be
permitted when the cartridge-present circuit 3440 indicates the
presence of a fastener cartridge 3420 in the end effector jaw
3402.
[0290] As described throughout the present disclosure, various
sensors, programs, and circuits can detect and measure numerous
characteristics of the surgical instrument and/or components
thereof, surgical use or operation, and/or the tissue and/or
operating site. For example, tissue thickness, the identification
of the instrument components, usage and feedback data from surgical
functions, and error or fault indications can be detected by the
surgical instrument. In certain instances, the fastener cartridge
can include a nonvolatile memory unit, which can be embedded or
removably coupled to the fastener cartridge, for example. Such a
nonvolatile memory unit can be in signal communication with the
microcontroller via hardware, such as the electrical contacts
described herein, radio frequency, or various other suitable forms
of data transmission. In such instances, the microcontroller can
communicate data and feedback to the nonvolatile memory unit in the
fastener cartridge, and thus, the fastener cartridge can store
information. In various instances, the information can be securely
stored and access thereto can be restricted as suitable and
appropriate for the circumstances.
[0291] In certain instances, the nonvolatile memory unit can
comprise information regarding the fastener cartridge
characteristics and/or the compatibility thereof with various other
components of the modular surgical system. For example, when the
fastener cartridge is loaded into an end effector, the nonvolatile
memory unit can provide compatibility information to the
microcontroller of the surgical system. In such instances, the
microcontroller can verify the validity or compatibility of the
modular assembly. For example, the microcontroller can confirm that
the handle component can fire the fastener cartridge and/or that
the fastener cartridge appropriate fits the end effector, for
example. In certain circumstances, the microcontroller can
communicate the compatibility or lack thereof to the operator of
the surgical system, and/or may prevent a surgical function if the
modular components are incompatible, for example.
[0292] As described herein, the surgical instrument can include a
sensor, which can cooperate with a magnet to detect various
characteristics of the surgical instrument, operation, and surgical
site. In certain instances, the sensor can comprise a Hall Effect
sensor and, in other instances, the sensor can comprise a
magnetoresistive sensor as depicted in FIGS. 68(A)-68(C), for
example. As described in greater detail herein, a surgical end
effector can comprise a first jaw, which can be configured to
receive a fastener cartridge, and a second jaw. The first jaw
and/or the fastener cartridge can comprise a magnetic element, such
as a permanent magnet, for example, and the second jaw can comprise
a magnetoresistive sensor, for example. In other instances, the
first jaw and/or the fastener cartridge can comprise a
magnetoresistive sensor, for example, and the second jaw can
comprise a magnetic element. The magnetoresistive sensor may have
various characteristics listed in the table in FIG. 68(C), for
example, and/or similar specifications, for example. In certain
instances, the change in resistance caused by movement of the
magnetic element relative to the magnetoresistive sensor can affect
and/or vary the properties of the magnetic circuit depicted in FIG.
68(B), for example.
[0293] In various instances, the magnetoresistive sensor can detect
the position of the magnetic element, and thus, can detect the
thickness of tissue clamped between the opposing first and second
jaws, for example. The magnetoresistive sensor can be in signal
communication with the microcontroller, and the magnetoresistive
sensor can wirelessly transmit data to an antenna in signal
communication with the microcontroller, for example. In various
instances, a passive circuit can comprise the magnetoresistive
sensor. Moreover, the antenna can be positioned in the end
effector, and can detect a wireless signal from the
magnetoresistive sensor and/or microprocessor operably coupled
thereto, for example. In such circumstances, an exposed electrical
connection between the end effector comprising the antenna, for
example, and the fastener cartridge comprising the magnetoresistive
sensor, for example, can be avoided. Furthermore, in various
instances, the antenna can be wired and/or in wireless
communication with the microcontroller of the surgical
instrument.
[0294] Tissue can contain fluid and, when the tissue is compressed,
the fluid may be pressed from the compressed tissue. For example,
when tissue is clamped between opposing jaws of a surgical end
effector, fluid may flow and/or be displaced from the clamped
tissue. Fluid flow or displacement in clamped tissue can depend on
various characteristics of the tissue, such as the thickness and/or
type of tissue, as well as various characteristics of the surgical
operation, such as the desired tissue compression and/or the
elapsed clamping time, for example. In various instances, fluid
displacement between the opposing jaws of an end effector may
contribute to malformation of staples formed between the opposing
jaws. For example, the displacement of fluid during and/or
following staple formation can induce bending and/or other
uncontrolled movement of a staple away from its desired or intended
formation. Accordingly, in various instances, it may be desirable
to control the firing stroke, e.g., to control the firing speed, in
relationship to the detected fluid flow, or lack thereof,
intermediate opposing jaws of a surgical end effector.
[0295] In various instances, the fluid displacement in clamped
tissue can be determined or approximated by various measurable
and/or detectable tissue characteristics. For example, the degree
of tissue compression can correspond to the degree of fluid
displacement in the clamped tissue. In various instances, a higher
degree of tissue compression can correspond to more fluid flow, for
example, and a reduced degree of tissue compression can correspond
to less fluid flow, for example. In various circumstances, a sensor
positioned in the end effector jaws can detect the force exerted on
the jaws by the compressed tissue. Additionally or alternatively, a
sensor on or operably associated with the cutting element can
detect the resistance on the cutting element as the cutting element
is advanced through, and transects, the clamped tissue. In such
circumstances, the detected cutting and/or firing resistance can
correspond to the degree of tissue compression. When tissue
compression is high, for example, the cutting element resistance
can be greater, and when tissue compression is lower, for example,
the cutting element resistance can be reduced. Correspondingly, the
cutting element resistance can indicate the amount of fluid
displacement.
[0296] In certain instances, the fluid displacement in clamped
tissue can be determined or approximated by the force required to
fire the cutting element, i.e., the force-to-fire. The
force-to-fire can correspond to the cutting element resistance, for
example. Furthermore, the force-to-fire can be measured or
approximated by a microcontroller in signal communication with the
electric motor that drives the cutting element. For example, where
the cutting element resistance is higher, the electric motor can
require more current to drive the cutting element through the
tissue. Similarly, if the cutting element resistance is lower, the
electric motor can require less current to drive the cutting
element through the tissue. In such instances, the microcontroller
can detect the amount of current drawn by the electric motor during
the firing stroke. For example, the microcontroller can include a
current sensor, which can detect the current utilized to fire the
cutting element through the tissue, for example.
[0297] Referring now to FIG. 60, a surgical instrument assembly or
system can be configured to detect the compressive force in the
clamped tissue. For example, in various instances, an electric
motor can drive the firing element, and a microcontroller can be in
signal communication with the electric motor. As the electric motor
drives the firing element, the microcontroller can determine the
current drawn by the electric motor, for example. In such
instances, the force-to-fire can correspond to the current drawn by
the electric motor throughout the firing stroke, as described
above. Referring still to FIG. 60, at step 3501, the
microcontroller of the surgical instrument can determine if the
current drawn by the electric motor increases during the firing
stroke and, if so, can calculate the percentage increase of the
current.
[0298] In various instances, the microcontroller can compare the
current draw increase during the firing stroke to a predefined
threshold value. For example, the predefined threshold value can be
5%, 10%, 25%, 50% and/or 100%, for example, and the microcontroller
can compare the current increase detected during a firing stroke to
the predefined threshold value. In other instances, the threshold
increase can be a value or range of values between 5% and 100%,
and, in still other instances, the threshold increase can be less
than 5% or greater than 100%, for example. For example, if the
predefined threshold value is 50%, the microcontroller can compare
the percentage of current draw change to 50%, for example. In
certain instances, the microcontroller can determine if the current
drawn by the electric motor during the firing stroke exceeds a
percentage of the maximum current or a baseline value. For example,
the microcontroller can determine if the current exceeds 5%, 10%,
25%, 50% and/or 100% of the maximum motor current. In other
instances, the microcontroller can compare the current drawn by the
electric motor during the firing stroke to a predefined baseline
value, for example.
[0299] In various instances, the microcontroller can utilize an
algorithm to determine the change in current drawn by the electric
motor during a firing stroke. For example, the current sensor can
detect the current drawn by the electric motor at various times
and/or intervals during the firing stroke. The current sensor can
continually detect the current drawn by the electric motor and/or
can intermittently detect the current draw by the electric motor.
In various instances, the algorithm can compare the most recent
current reading to the immediately proceeding current reading, for
example. Additionally or alternatively, the algorithm can compare a
sample reading within a time period X to a previous current
reading. For example, the algorithm can compare the sample reading
to a previous sample reading within a previous time period X, such
as the immediately proceeding time period X, for example. In other
instances, the algorithm can calculate the trending average of
current drawn by the motor. The algorithm can calculate the average
current draw during a time period X that includes the most recent
current reading, for example, and can compare that average current
draw to the average current draw during an immediately proceeding
time period time X, for example.
[0300] Referring still to FIG. 60, if the microcontroller detects a
current increase that is greater than the threshold change or
value, the microcontroller can proceed to step 3503, and the firing
speed of the firing element can be reduced. For example, the
microcontroller can communicate with the electric motor to slow the
firing speed of the firing element. For example, the firing speed
can be reduced by a predefined step unit and/or a predefined
percentage. In various instances, the microcontroller can comprise
a velocity control module, which can affect changes in the cutting
element speed and/or can maintain the cutting element speed. The
velocity control module can comprise a resistor, a variable
resistor, a pulse width modulation circuit, and/or a frequency
modulation circuit, for example. Referring still to FIG. 60, if the
current increase is less than the threshold value, the
microcontroller can proceed to step 3505, wherein the firing speed
of the firing element can be maintained, for example. In various
circumstances, the microcontroller can continue to monitor the
current drawn by the electric motor and changes thereto during at
least a portion of the firing stroke. Moreover, the microcontroller
and/or velocity control module thereof can adjust the firing
element velocity throughout the firing stroke in accordance with
the detected current draw. In such instances, controlling the
firing speed based on the approximated fluid flow or displacement
in the clamped tissue, for example, can reduce the incidence of
staple malformation in the clamped tissue.
[0301] Referring now to FIG. 61, in various instances, the
microcontroller can adjust the firing element velocity by pausing
the firing element for a predefined period of time. For example,
similar to the embodiment depicted in FIG. 60, if the
microcontroller detects a current draw that exceeds a predefined
threshold value at step 3511, the microcontroller can proceed to
step 3513 and the firing element can be paused. For example, the
microcontroller can pause movement and/or translation of the firing
element for one second if the current increase measured by the
microcontroller exceeds the threshold value. In other instances,
the firing stroke can be paused for a fraction of a second and/or
more than one second, for example. Similar to the process described
above, if the current draw increase is less than the threshold
value, the microcontroller can proceed to step 3515 and the firing
element can continue to progress through the firing stroke without
adjusting the velocity of the firing element. In certain instances,
the microcontroller can be configured to pause and slow the firing
element during a firing stroke. For example, for a first increase
in current draw, the firing element can be paused, and for a
second, different increase in current draw, the velocity of the
firing element can be reduced. In still other circumstances, the
microcontroller can command an increase in the velocity of the
firing element if the current draw decreases below a threshold
value, for example.
[0302] The entire disclosures of:
[0303] U.S. Pat. No. 5,403,312, entitled ELECTROSURGICAL HEMOSTATIC
DEVICE, which issued on Apr. 4, 1995;
[0304] U.S. Pat. No. 7,000,818, entitled SURGICAL STAPLING
INSTRUMENT HAVING SEPARATE DISTINCT CLOSING AND FIRING SYSTEMS,
which issued on Feb. 21, 2006;
[0305] U.S. Pat. No. 7,422,139, entitled MOTOR-DRIVEN SURGICAL
CUTTING AND FASTENING INSTRUMENT WITH TACTILE POSITION FEEDBACK,
which issued on Sep. 9, 2008;
[0306] U.S. Pat. No. 7,464,849, entitled ELECTRO-MECHANICAL
SURGICAL INSTRUMENT WITH CLOSURE SYSTEM AND ANVIL ALIGNMENT
COMPONENTS, which issued on Dec. 16, 2008;
[0307] U.S. Pat. No. 7,670,334, entitled SURGICAL INSTRUMENT HAVING
AN ARTICULATING END EFFECTOR, which issued on Mar. 2, 2010;
[0308] U.S. Pat. No. 7,753,245, entitled SURGICAL STAPLING
INSTRUMENTS, which issued on Jul. 13, 2010;
[0309] U.S. Pat. No. 8,393,514, entitled SELECTIVELY ORIENTABLE
IMPLANTABLE FASTENER CARTRIDGE, which issued on Mar. 12, 2013;
[0310] U.S. patent application Ser. No. 11/343,803, entitled
SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES;
[0311] U.S. patent application Ser. No. 12/031,573, entitled
SURGICAL CUTTING AND FASTENING INSTRUMENT HAVING RF ELECTRODES,
filed Feb. 14, 2008;
[0312] U.S. patent application Ser. No. 12/031,873, entitled END
EFFECTORS FOR A SURGICAL CUTTING AND STAPLING INSTRUMENT, filed
Feb. 15, 2008, now U.S. Pat. No. 7,980,443
[0313] U.S. patent application Ser. No. 12/235,782, entitled
MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT, now U.S. Pat. No.
8,210,411;
[0314] U.S. patent application Ser. No. 12/249,117, entitled
POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY
RETRACTABLE FIRING SYSTEM, now U.S. Patent Application Publication
No. 2010/0089970;
[0315] U.S. patent application Ser. No. 12/647,100, entitled
MOTOR-DRIVEN SURGICAL CUTTING INSTRUMENT WITH ELECTRIC ACTUATOR
DIRECTIONAL CONTROL ASSEMBLY, filed Dec. 24, 2009;
[0316] U.S. patent application Ser. No. 12/893,461, entitled STAPLE
CARTRIDGE, filed Sep. 29, 2012, now U.S. Patent Application
Publication No. 2012/0074198;
[0317] U.S. patent application Ser. No. 13/036,647, entitled
SURGICAL STAPLING INSTRUMENT, filed Feb. 28, 2011, now U.S. Patent
Application Publication No. 2011/0226837;
[0318] U.S. patent application Ser. No. 13/118,241, entitled
SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT
ARRANGEMENTS, now U.S. Patent Application Publication No.
2012/0298719;
[0319] U.S. patent application Ser. No. 13/524,049, entitled
ARTICULATABLE SURGICAL INSTRUMENT COMPRISING A FIRING DRIVE, filed
on Jun. 15, 2012;
[0320] U.S. patent application Ser. No. 13/800,025, entitled STAPLE
CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,
2013;
[0321] U.S. patent application Ser. No. 13/800,067, entitled STAPLE
CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, filed on Mar. 13,
2013;
[0322] U.S. Patent Application Pub. No. 2007/0175955, entitled
SURGICAL CUTTING AND FASTENING INSTRUMENT WITH CLOSURE TRIGGER
LOCKING MECHANISM, filed Jan. 31, 2006; and
[0323] U.S. Patent Application Publication No. 2010/0264194,
entitled SURGICAL STAPLING INSTRUMENT WITH AN ARTICULATABLE END
EFFECTOR, filed Apr. 22, 2010, are hereby incorporated by reference
herein.
[0324] In accordance with various embodiments, the surgical
instruments described herein may comprise one or more processors
(e.g., microprocessor, microcontroller) coupled to various sensors.
In addition, to the processor(s), a storage (having operating
logic) and communication interface, are coupled to each other.
[0325] The processor may be configured to execute the operating
logic. The processor may be any one of a number of single or
multi-core processors known in the art. The storage may comprise
volatile and non-volatile storage media configured to store
persistent and temporal (working) copy of the operating logic.
[0326] In various embodiments, the operating logic may be
configured to process the collected biometric associated with
motion data of the user, as described above. In various
embodiments, the operating logic may be configured to perform the
initial processing, and transmit the data to the computer hosting
the application to determine and generate instructions. For these
embodiments, the operating logic may be further configured to
receive information from and provide feedback to a hosting
computer. In alternate embodiments, the operating logic may be
configured to assume a larger role in receiving information and
determining the feedback. In either case, whether determined on its
own or responsive to instructions from a hosting computer, the
operating logic may be further configured to control and provide
feedback to the user.
[0327] In various embodiments, the operating logic may be
implemented in instructions supported by the instruction set
architecture (ISA) of the processor, or in higher level languages
and compiled into the supported ISA. The operating logic may
comprise one or more logic units or modules. The operating logic
may be implemented in an object oriented manner. The operating
logic may be configured to be executed in a multi-tasking and/or
multi-thread manner. In other embodiments, the operating logic may
be implemented in hardware such as a gate array.
[0328] In various embodiments, the communication interface may be
configured to facilitate communication between a peripheral device
and the computing system. The communication may include
transmission of the collected biometric data associated with
position, posture, and/or movement data of the user's body part(s)
to a hosting computer, and transmission of data associated with the
tactile feedback from the host computer to the peripheral device.
In various embodiments, the communication interface may be a wired
or a wireless communication interface. An example of a wired
communication interface may include, but is not limited to, a
Universal Serial Bus (USB) interface. An example of a wireless
communication interface may include, but is not limited to, a
Bluetooth interface.
[0329] For various embodiments, the processor may be packaged
together with the operating logic. In various embodiments, the
processor may be packaged together with the operating logic to form
a System in Package (SiP). In various embodiments, the processor
may be integrated on the same die with the operating logic. In
various embodiments, the processor may be packaged together with
the operating logic to form a System on Chip (SoC).
[0330] Various embodiments may be described herein in the general
context of computer executable instructions, such as software,
program modules, and/or engines being executed by a processor.
Generally, software, program modules, and/or engines include any
software element arranged to perform particular operations or
implement particular abstract data types. Software, program
modules, and/or engines can include routines, programs, objects,
components, data structures and the like that perform particular
tasks or implement particular abstract data types. An
implementation of the software, program modules, and/or engines
components and techniques may be stored on and/or transmitted
across some form of computer-readable media. In this regard,
computer-readable media can be any available medium or media
useable to store information and accessible by a computing device.
Some embodiments also may be practiced in distributed computing
environments where operations are performed by one or more remote
processing devices that are linked through a communications
network. In a distributed computing environment, software, program
modules, and/or engines may be located in both local and remote
computer storage media including memory storage devices. A memory
such as a random access memory (RAM) or other dynamic storage
device may be employed for storing information and instructions to
be executed by the processor. The memory also may be used for
storing temporary variables or other intermediate information
during execution of instructions to be executed by the
processor.
[0331] Although some embodiments may be illustrated and described
as comprising functional components, software, engines, and/or
modules performing various operations, it can be appreciated that
such components or modules may be implemented by one or more
hardware components, software components, and/or combination
thereof. The functional components, software, engines, and/or
modules may be implemented, for example, by logic (e.g.,
instructions, data, and/or code) to be executed by a logic device
(e.g., processor). Such logic may be stored internally or
externally to a logic device on one or more types of
computer-readable storage media. In other embodiments, the
functional components such as software, engines, and/or modules may
be implemented by hardware elements that may include processors,
microprocessors, circuits, circuit elements (e.g., transistors,
resistors, capacitors, inductors, and so forth), integrated
circuits, application specific integrated circuits (ASIC),
programmable logic devices (PLD), digital signal processors (DSP),
field programmable gate array (FPGA), logic gates, registers,
semiconductor device, chips, microchips, chip sets, and so
forth.
[0332] Examples of software, engines, and/or modules may include
software components, programs, applications, computer programs,
application programs, system programs, machine programs, operating
system software, middleware, firmware, software modules, routines,
subroutines, functions, methods, procedures, software interfaces,
application program interfaces (API), instruction sets, computing
code, computer code, code segments, computer code segments, words,
values, symbols, or any combination thereof. Determining whether an
embodiment is implemented using hardware elements and/or software
elements may vary in accordance with any number of factors, such as
desired computational rate, power levels, heat tolerances,
processing cycle budget, input data rates, output data rates,
memory resources, data bus speeds and other design or performance
constraints.
[0333] One or more of the modules described herein may comprise one
or more embedded applications implemented as firmware, software,
hardware, or any combination thereof. One or more of the modules
described herein may comprise various executable modules such as
software, programs, data, drivers, application program interfaces
(APIs), and so forth. The firmware may be stored in a memory of the
controller 2016 and/or the controller 2022 which may comprise a
nonvolatile memory (NVM), such as in bit-masked read-only memory
(ROM) or flash memory. In various implementations, storing the
firmware in ROM may preserve flash memory. The nonvolatile memory
(NVM) may comprise other types of memory including, for example,
programmable ROM (PROM), erasable programmable ROM (EPROM),
electrically erasable programmable ROM (EEPROM), or battery backed
random-access memory (RAM) such as dynamic RAM (DRAM),
Double-Data-Rate DRAM (DDRAM), and/or synchronous DRAM (SDRAM).
[0334] In some cases, various embodiments may be implemented as an
article of manufacture. The article of manufacture may include a
computer readable storage medium arranged to store logic,
instructions and/or data for performing various operations of one
or more embodiments. In various embodiments, for example, the
article of manufacture may comprise a magnetic disk, optical disk,
flash memory or firmware containing computer program instructions
suitable for execution by a general purpose processor or
application specific processor. The embodiments, however, are not
limited in this context.
[0335] The functions of the various functional elements, logical
blocks, modules, and circuits elements described in connection with
the embodiments disclosed herein may be implemented in the general
context of computer executable instructions, such as software,
control modules, logic, and/or logic modules executed by the
processing unit. Generally, software, control modules, logic,
and/or logic modules comprise any software element arranged to
perform particular operations. Software, control modules, logic,
and/or logic modules can comprise routines, programs, objects,
components, data structures and the like that perform particular
tasks or implement particular abstract data types. An
implementation of the software, control modules, logic, and/or
logic modules and techniques may be stored on and/or transmitted
across some form of computer-readable media. In this regard,
computer-readable media can be any available medium or media
useable to store information and accessible by a computing device.
Some embodiments also may be practiced in distributed computing
environments where operations are performed by one or more remote
processing devices that are linked through a communications
network. In a distributed computing environment, software, control
modules, logic, and/or logic modules may be located in both local
and remote computer storage media including memory storage
devices.
[0336] Additionally, it is to be appreciated that the embodiments
described herein illustrate example implementations, and that the
functional elements, logical blocks, modules, and circuits elements
may be implemented in various other ways which are consistent with
the described embodiments. Furthermore, the operations performed by
such functional elements, logical blocks, modules, and circuits
elements may be combined and/or separated for a given
implementation and may be performed by a greater number or fewer
number of components or modules. As will be apparent to those of
skill in the art upon reading the present disclosure, each of the
individual embodiments described and illustrated herein has
discrete components and features which may be readily separated
from or combined with the features of any of the other several
aspects without departing from the scope of the present disclosure.
Any recited method can be carried out in the order of events
recited or in any other order which is logically possible.
[0337] It is worthy to note that any reference to "one embodiment"
or "an embodiment" means that a particular feature, structure, or
characteristic described in connection with the embodiment is
comprised in at least one embodiment. The appearances of the phrase
"in one embodiment" or "in one aspect" in the specification are not
necessarily all referring to the same embodiment.
[0338] Unless specifically stated otherwise, it may be appreciated
that terms such as "processing," "computing," "calculating,"
"determining," or the like, refer to the action and/or processes of
a computer or computing system, or similar electronic computing
device, such as a general purpose processor, a DSP, ASIC, FPGA or
other programmable logic device, discrete gate or transistor logic,
discrete hardware components, or any combination thereof designed
to perform the functions described herein that manipulates and/or
transforms data represented as physical quantities (e.g.,
electronic) within registers and/or memories into other data
similarly represented as physical quantities within the memories,
registers or other such information storage, transmission or
display devices.
[0339] It is worthy to note that some embodiments may be described
using the expression "coupled" and "connected" along with their
derivatives. These terms are not intended as synonyms for each
other. For example, some embodiments may be described using the
terms "connected" and/or "coupled" to indicate that two or more
elements are in direct physical or electrical contact with each
other. The term "coupled," however, also may mean that two or more
elements are not in direct contact with each other, but yet still
co-operate or interact with each other. With respect to software
elements, for example, the term "coupled" may refer to interfaces,
message interfaces, application program interface (API), exchanging
messages, and so forth.
[0340] It should be appreciated that 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 material 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.
[0341] The disclosed embodiments have application in conventional
endoscopic and open surgical instrumentation as well as application
in robotic-assisted surgery.
[0342] Embodiments of 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. Embodiments may, in either or both cases, be
reconditioned for reuse after at least one use. Reconditioning may
include any combination of the steps of disassembly of the device,
followed by cleaning or replacement of particular pieces, and
subsequent reassembly. In particular, embodiments of the device may
be disassembled, and any number of the particular pieces or parts
of the device may be selectively replaced or removed in any
combination. Upon cleaning and/or replacement of particular parts,
embodiments of the device may 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 may 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.
[0343] By way of example only, embodiments described herein may be
processed before surgery. First, a new or used instrument may be
obtained and when necessary cleaned. The instrument may 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 may then be placed in a field of
radiation that can penetrate the container, such as gamma
radiation, x-rays, or high-energy electrons. The radiation may kill
bacteria on the instrument and in the container. The sterilized
instrument may then be stored in the sterile container. The sealed
container may keep the instrument sterile until it is opened in a
medical facility. A device also may be sterilized using any other
technique known in the art, including but not limited to beta or
gamma radiation, ethylene oxide, or steam.
[0344] One skilled in the art will recognize that the herein
described components (e.g., operations), devices, objects, and the
discussion accompanying them are used as examples for the sake of
conceptual clarity and that various configuration modifications are
contemplated. Consequently, as used herein, the specific exemplars
set forth and the accompanying discussion are intended to be
representative of their more general classes. In general, use of
any specific exemplar is intended to be representative of its
class, and the non-inclusion of specific components (e.g.,
operations), devices, and objects should not be taken limiting.
[0345] With respect to the use of substantially any plural and/or
singular terms herein, those having skill in the art can translate
from the plural to the singular and/or from the singular to the
plural as is appropriate to the context and/or application. The
various singular/plural permutations are not expressly set forth
herein for sake of clarity.
[0346] The herein described subject matter sometimes illustrates
different components contained within, or connected with, different
other components. It is to be understood that such depicted
architectures are merely examples and that in fact many other
architectures may be implemented which achieve the same
functionality. In a conceptual sense, any arrangement of components
to achieve the same functionality is effectively "associated" such
that the desired functionality is achieved. Hence, any two
components herein combined to achieve a particular functionality
can be seen as "associated with" each other such that the desired
functionality is achieved, irrespective of architectures or
intermedial components. Likewise, any two components so associated
also can be viewed as being "operably connected," or "operably
coupled," to each other to achieve the desired functionality, and
any two components capable of being so associated also can be
viewed as being "operably couplable," to each other to achieve the
desired functionality. Specific examples of operably couplable
include but are not limited to physically mateable and/or
physically interacting components, and/or wirelessly interactable,
and/or wirelessly interacting components, and/or logically
interacting, and/or logically interactable components.
[0347] Some aspects may be described using the expression "coupled"
and "connected" along with their derivatives. It should be
understood that these terms are not intended as synonyms for each
other. For example, some aspects may be described using the term
"connected" to indicate that two or more elements are in direct
physical or electrical contact with each other. In another example,
some aspects may be described using the term "coupled" to indicate
that two or more elements are in direct physical or electrical
contact. The term "coupled," however, also may mean that two or
more elements are not in direct contact with each other, but yet
still co-operate or interact with each other.
[0348] In some instances, one or more components may be referred to
herein as "configured to," "configurable to," "operable/operative
to," "adapted/adaptable," "able to," "conformable/conformed to,"
etc. Those skilled in the art will recognize that "configured to"
can generally encompass active-state components and/or
inactive-state components and/or standby-state components, unless
context requires otherwise.
[0349] While particular aspects of the present subject matter
described herein have been shown and described, it will be apparent
to those skilled in the art that, based upon the teachings herein,
changes and modifications may be made without departing from the
subject matter described herein and its broader aspects and,
therefore, the appended claims are to encompass within their scope
all such changes and modifications as are within the true scope of
the subject matter described herein. It will be understood by those
within the art that, in general, terms used herein, and especially
in the appended claims (e.g., bodies of the appended claims) are
generally intended as "open" terms (e.g., the term "including"
should be interpreted as "including but not limited to," the term
"having" should be interpreted as "having at least," the term
"includes" should be interpreted as "includes but is not limited
to," etc.). It will be further understood by those within the art
that when a specific number of an introduced claim recitation is
intended, such an intent will be explicitly recited in the claim,
and in the absence of such recitation no such intent is present.
For example, as an aid to understanding, the following appended
claims may contain usage of the introductory phrases "at least one"
and "one or more" to introduce claim recitations. However, the use
of such phrases should not be construed to imply that the
introduction of a claim recitation by the indefinite articles "a"
or "an" limits any particular claim containing such introduced
claim recitation to claims containing only one such recitation,
even when the same claim includes the introductory phrases "one or
more" or "at least one" and indefinite articles such as "a" or "an"
(e.g., "a" and/or "an" should typically be interpreted to mean "at
least one" or "one or more"); the same holds true for the use of
definite articles used to introduce claim recitations.
[0350] In addition, even when a specific number of an introduced
claim recitation is explicitly recited, those skilled in the art
will recognize that such recitation should typically be interpreted
to mean at least the recited number (e.g., the bare recitation of
"two recitations," without other modifiers, typically means at
least two recitations, or two or more recitations). Furthermore, in
those instances where a convention analogous to "at least one of A,
B, and C, etc." is used, in general such a construction is intended
in the sense one having skill in the art would understand the
convention (e.g., "a system having at least one of A, B, and C"
would include but not be limited to systems that have A alone, B
alone, C alone, A and B together, A and C together, B and C
together, and/or A, B, and C together, etc.). In those instances
where a convention analogous to "at least one of A, B, or C, etc."
is used, in general such a construction is intended in the sense
one having skill in the art would understand the convention (e.g.,
"a system having at least one of A, B, or C" would include but not
be limited to systems that have A alone, B alone, C alone, A and B
together, A and C together, B and C together, and/or A, B, and C
together, etc.). It will be further understood by those within the
art that typically a disjunctive word and/or phrase presenting two
or more alternative terms, whether in the description, claims, or
drawings, should be understood to contemplate the possibilities of
including one of the terms, either of the terms, or both terms
unless context dictates otherwise. For example, the phrase "A or B"
will be typically understood to include the possibilities of "A" or
"B" or "A and B."
[0351] With respect to the appended claims, those skilled in the
art will appreciate that recited operations therein may generally
be performed in any order. Also, although various operational flows
are presented in a sequence(s), it should be understood that the
various operations may be performed in other orders than those
which are illustrated, or may be performed concurrently. Examples
of such alternate orderings may include overlapping, interleaved,
interrupted, reordered, incremental, preparatory, supplemental,
simultaneous, reverse, or other variant orderings, unless context
dictates otherwise. Furthermore, terms like "responsive to,"
"related to," or other past-tense adjectives are generally not
intended to exclude such variants, unless context dictates
otherwise.
[0352] In summary, numerous benefits have been described which
result from employing the concepts described herein. The foregoing
description of the one or more embodiments has been presented for
purposes of illustration and description. It is not intended to be
exhaustive or limiting to the precise form disclosed. Modifications
or variations are possible in light of the above teachings. The one
or more embodiments were chosen and described in order to
illustrate principles and practical application to thereby enable
one of ordinary skill in the art to utilize the various embodiments
and with various modifications as are suited to the particular use
contemplated. It is intended that the claims submitted herewith
define the overall scope.
* * * * *