U.S. patent application number 16/112117 was filed with the patent office on 2019-05-02 for surgical instrument systems comprising lockout mechanisms.
The applicant listed for this patent is Ethicon LLC. Invention is credited to Jason L. Harris, Frederick E. Shelton, IV.
Application Number | 20190125476 16/112117 |
Document ID | / |
Family ID | 66245017 |
Filed Date | 2019-05-02 |
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United States Patent
Application |
20190125476 |
Kind Code |
A1 |
Shelton, IV; Frederick E. ;
et al. |
May 2, 2019 |
SURGICAL INSTRUMENT SYSTEMS COMPRISING LOCKOUT MECHANISMS
Abstract
A surgical instrument system comprising a surgical instrument
and a housing is disclosed. The housing comprises a handle
assembly, at least one motor, and a drive shaft. The surgical
instrument system comprises a shaft assembly configured to be
attached to the housing. The shaft assembly comprises a control
circuit and a locking mechanism. The locking mechanism prevents
movement of the drive shaft if the shaft assembly is not attached
to the surgical instrument in an orientation which enables the
operation of the surgical instrument. The locking mechanism
comprises sensing means for determining whether the locking
mechanism is actively engaged.
Inventors: |
Shelton, IV; Frederick E.;
(Hillsboro, OH) ; Harris; Jason L.; (Lebanon,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ethicon LLC |
Guaynabo |
PR |
US |
|
|
Family ID: |
66245017 |
Appl. No.: |
16/112117 |
Filed: |
August 24, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62578793 |
Oct 30, 2017 |
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62578804 |
Oct 30, 2017 |
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62578817 |
Oct 30, 2017 |
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62578835 |
Oct 30, 2017 |
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62578844 |
Oct 30, 2017 |
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62578855 |
Oct 30, 2017 |
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62665129 |
May 1, 2018 |
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62665139 |
May 1, 2018 |
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62665177 |
May 1, 2018 |
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62665128 |
May 1, 2018 |
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62665192 |
May 1, 2018 |
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62665134 |
May 1, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A61B 17/0482 20130101;
A61B 34/30 20160201; A61B 90/98 20160201; A61B 2017/2825 20130101;
G06F 3/147 20130101; A61B 17/285 20130101; A61B 18/1445 20130101;
A61B 2017/00734 20130101; A61B 2018/00767 20130101; A61B 17/2909
20130101; A61B 2017/0046 20130101; A61B 17/282 20130101; A61B 17/00
20130101; A61B 2017/00393 20130101; A61B 2017/00438 20130101; A61B
2017/00464 20130101; A61B 2018/00642 20130101; G09G 3/38 20130101;
A61B 2018/00404 20130101; A61B 2018/1266 20130101; F16D 27/09
20130101; A61B 17/0491 20130101; A61B 17/062 20130101; A61B
2017/00039 20130101; F16D 27/12 20130101; B33Y 80/00 20141201; A61B
17/3468 20130101; A61B 2017/00473 20130101; A61B 2018/00678
20130101; A61B 2018/146 20130101; A61B 17/068 20130101; A61B
2017/00026 20130101; A61B 2018/00136 20130101; A61B 2018/00595
20130101; A61B 2018/00875 20130101; A61B 2017/2902 20130101; A61B
2017/2903 20130101; A61B 2017/00407 20130101; A61B 2017/00526
20130101; A61B 2017/06076 20130101; G09G 2380/08 20130101; A61B
18/1206 20130101; A61B 2017/00057 20130101; A61B 2018/1452
20130101; A61B 17/0625 20130101; A61B 2017/00119 20130101; A61B
2017/00128 20130101; A61B 2017/00477 20130101; A61B 2017/2925
20130101; G09G 3/344 20130101; A61B 2017/2931 20130101; A61B
2018/00672 20130101; A61B 17/0469 20130101; A61B 17/0483 20130101;
A61B 2017/00017 20130101; A61B 2017/00061 20130101; A61B 2017/00115
20130101; A61B 2017/00424 20130101; A61B 17/06066 20130101; A61B
34/76 20160201; A61B 2017/00367 20130101; A61B 2018/0072 20130101;
A61B 2018/00892 20130101; A61B 2090/0811 20160201; F16D 27/004
20130101; A61B 17/2841 20130101; A61B 90/03 20160201; A61B
2017/2911 20130101; A61B 2017/2927 20130101; A61B 17/06114
20130101; A61B 17/06133 20130101; A61B 2017/00327 20130101; A61B
2017/2943 20130101; A61B 2017/2945 20130101; A61B 2018/00178
20130101; A61B 17/06004 20130101; A61B 2017/2845 20130101; A61B
2018/00577 20130101; A61B 2018/0063 20130101; A61B 17/295 20130101;
A61B 2017/00212 20130101; A61B 2018/00208 20130101; A61B 17/105
20130101; A61B 17/3421 20130101; A61B 2018/00077 20130101; A61B
2018/126 20130101; A61B 17/1285 20130101; A61B 17/2833 20130101;
A61B 2018/00827 20130101; G09G 3/3648 20130101; A61B 17/128
20130101; A61B 2017/320044 20130101; A61B 2017/00221 20130101; A61B
2018/00702 20130101; A61B 2018/1253 20130101; A61B 2018/00601
20130101; A61B 17/29 20130101; A61B 2017/2923 20130101; A61B
2017/2929 20130101; A61B 2090/035 20160201; A61B 17/3201 20130101;
A61B 2017/0003 20130101; A61B 2017/00075 20130101; A61B 2017/00398
20130101; A61B 2018/00083 20130101; A61B 2018/00696 20130101; A61B
2017/06052 20130101; A61B 2017/2926 20130101; F16D 11/16 20130101;
A61B 2018/00708 20130101; A61B 2018/1457 20130101; F16D 27/108
20130101 |
International
Class: |
A61B 90/00 20060101
A61B090/00; A61B 17/34 20060101 A61B017/34; A61B 17/10 20060101
A61B017/10 |
Claims
1. A surgical instrument system, comprising: a surgical instrument;
a housing, comprising: a handle assembly; at least one motor; and a
drive shaft; a shaft assembly configured to be attached to a distal
end of said housing, wherein said shaft assembly comprises: a
control circuit; and a locking mechanism, wherein said locking
mechanism prevents movement of said drive shaft if said shaft
assembly is not attached to said surgical instrument in an
orientation which enables operation of said surgical instrument,
and wherein said locking mechanism further comprises sensing means
for determining whether said locking mechanism is actively engaged;
and an end effector attachable to a distal end of said shaft
assembly.
2. The surgical instrument system of claim 1, wherein said control
circuit further comprises at least one safety feature.
3. The surgical instrument system of claim 1, wherein said locking
mechanism is configured to prevent the actuation of said surgical
instrument.
4. The surgical instrument system of claim 1, wherein said locking
mechanism is configured to prevent activation of said motor.
5. The surgical instrument system of claim 1, wherein said locking
mechanism prevents movement of said shaft assembly when said shaft
assembly is not attached to said housing.
6. The surgical instrument system of claim 1, wherein said locking
mechanism is configured to detect whether said end effector is in a
usable state.
7. The surgical instrument system of claim 1, wherein said sensing
means is configured to enable haptic feedback of said motor in
order to alert a user of a state of said surgical instrument.
8-28. (canceled)
29. A surgical instrument system configured to treat the tissue of
a patient, comprising: a shaft assembly, comprising: a longitudinal
axis; an end effector, comprising: a movable member; and an
actuator configured to deploy a plurality of surgical clips; an
articulation joint rotatably connecting said end effector to said
shaft; a rotation drive shaft configured to rotate said shaft about
said longitudinal axis; a firing drive shaft configured to deploy
said movable member; and an articulation drive shaft configured to
articulate said end effector relative to said shaft; a first
handle, comprising: a rotation drive system configured to drive
said rotation drive shaft; a firing drive system configured to
drive said firing drive shaft; and an articulation drive system
configured to drive said articulation drive shaft; and a second
handle, comprising: a rotation drive lockout configured to lock
said rotation drive shaft; and a firing drive system configured to
drive said firing drive shaft.
30. A surgical instrument system configured to treat the tissue of
a patient, comprising: a shaft assembly, comprising: a longitudinal
axis; an end effector, comprising: a movable member; and an
actuator configured to deploy a plurality of clips; an articulation
joint rotatably connecting said end effector to said shaft; a
rotation drive shaft configured to rotate said shaft about said
longitudinal axis; a firing drive shaft configured to deploy said
movable member; and an articulation drive shaft configured to
articulate said end effector relative to said shaft; a first
handle, comprising: a rotation drive system configured to drive
said rotation drive shaft; a firing drive system configured to
drive said firing drive shaft; and an articulation drive system
configured to drive said articulation drive shaft; and a second
handle, comprising: an articulation drive lockout configured to
lock said articulation drive shaft; and a firing drive system
configured to drive said firing drive shaft.
31. A surgical instrument system configured to treat the tissue of
a patient, comprising: a shaft assembly configured to perform a
first function, a second function, and a third function, wherein
the shaft assembly comprises: a first drive shaft configured to
perform said first function; a second drive shaft configured to
perform said second function; and a third drive shaft configured to
perform said third function; a first handle, comprising: a first
drive system configured to drive said first drive shaft; a second
drive system configured to drive said second drive shaft; and a
third drive system configured to drive said third drive shaft; a
second handle, comprising: a first drive lockout configured to lock
said first drive shaft; and a second drive system configured to
drive said second drive shaft.
32. The surgical instrument system of claim 31, wherein said second
handle comprises a drive lockout configured to lock said third
drive shaft.
33. A surgical instrument system configured to treat the tissue of
a patient, comprising: a shaft assembly, comprising: a first drive
system configured to perform a first function; a second drive
system configured to perform a second function; a first lockout
configured to selectively engage said first drive system and
prevent said first drive system from performing said first
function; and a second lockout configured to selectively engage
said second drive system and prevent said second drive system from
performing said second function; a first handle comprising a first
operating system configured to operate said first drive system and
a second operating system configured to operate said second drive
system, wherein said first lockout and said second lockout are
disengaged when said shaft assembly is assembled to said first
handle; and a second handle comprising a first operating system
configured to operate said first drive system but not comprising a
second operating system configured to operate said second drive
system, wherein said first lockout is disengaged and said second
lockout is engaged when said shaft assembly is assembled to said
second handle.
34. The surgical instrument system of claim 33, wherein said first
lockout and said second lockouts are in their engaged states when
said shaft assembly is not assembled to either said first handle or
said second handle.
35. A surgical instrument system, comprising: a handle comprising a
drive system including an electric motor; a shaft assembly
attachable to said handle, wherein said shaft assembly comprises a
drive shaft that is operably engaged with said drive system when
said shaft assembly is attached to said handle, wherein said drive
system is configured to drive said drive shaft when said shaft
assembly is in a usable condition; a sensor system configured to
evaluate the condition of said shaft assembly; and a control system
in communication with said drive system and said sensor system,
wherein said control system is configured to prevent the operation
of said electric motor if said shaft assembly is in an unusable
condition.
36. The surgical instrument system of claim 35, further comprising
a haptic feedback system in communication with said control system,
wherein said control system is configured to actuate said haptic
feedback system to provide haptic feedback to the user of said
surgical instrument system when said sensor system detects that
said shaft assembly is in an unusable condition.
37. The surgical instrument system of claim 35, wherein said handle
further comprises a second drive system, wherein said shaft
assembly further comprises a second drive shaft operably engageable
with said second drive system when said shaft assembly is attached
to said handle, and wherein said control system is configured to
use said second drive system when said sensor system detects that
said shaft assembly is in an unusable condition.
38-41. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This non-provisional application claims the benefit under 35
U.S.C. .sctn. 119(e) of U.S. Provisional Patent Application Ser.
No. 62/578,793, entitled SURGICAL INSTRUMENT WITH REMOTE RELEASE,
filed Oct. 30, 2017, of U.S. Provisional Patent Application Ser.
No. 62/578,804, entitled SURGICAL INSTRUMENT HAVING DUAL ROTATABLE
MEMBERS TO EFFECT DIFFERENT TYPES OF END EFFECTOR MOVEMENT, filed
Oct. 30, 2017, of U.S. Provisional Patent Application Ser. No.
62/578,817, entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE
SELECTIVELY ACTUATING MULTIPLE END EFFECTOR FUNCTIONS, filed Oct.
30, 2017, of U.S. Provisional Patent Application Ser. No.
62/578,835, entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE
SELECTIVELY ACTUATING MULTIPLE END EFFECTOR FUNCTIONS, filed Oct.
30, 2017, of U.S. Provisional Patent Application Ser. No.
62/578,844, entitled SURGICAL INSTRUMENT WITH MODULAR POWER
SOURCES, filed Oct. 30, 2017, and of U.S. Provisional Patent
Application Ser. No. 62/578,855, entitled SURGICAL INSTRUMENT WITH
SENSOR AND/OR CONTROL SYSTEMS, filed Oct. 30, 2017, the disclosures
of which are incorporated by reference herein in their entirety.
This non-provisional application claims the benefit under 35 U.S.C.
.sctn. 119(e) of U.S. Provisional Patent Application Ser. No.
62/665,129, entitled SURGICAL SUTURING SYSTEMS, filed May 1, 2018,
of U.S. Provisional Patent Application Ser. No. 62/665,139,
entitled SURGICAL INSTRUMENTS COMPRISING CONTROL SYSTEMS, filed May
1, 2018, of U.S. Provisional Patent Application Ser. No.
62/665,177, entitled SURGICAL INSTRUMENTS COMPRISING HANDLE
ARRANGEMENTS, filed May 1, 2018, of U.S. Provisional Patent
Application Ser. No. 62/665,128, entitled MODULAR SURGICAL
INSTRUMENTS, filed May 1, 2018, of U.S. Provisional Patent
Application Ser. No. 62/665,192, entitled SURGICAL DISSECTORS,
filed May 1, 2018, and of U.S. Provisional Patent Application Ser.
No. 62/665,134, entitled SURGICAL CLIP APPLIER, filed May 1, 2018,
the disclosures of which are incorporated by reference herein in
their entirety.
BACKGROUND
[0002] The present invention relates to surgical systems and, in
various arrangements, to grasping instruments that are designed to
grasp the tissue of a patient, dissecting instruments configured to
manipulate the tissue of a patient, clip appliers configured to
clip the tissue of a patient, and suturing instruments configured
to suture the tissue of a patient, among others.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Various features of the embodiments described herein,
together with advantages thereof, may be understood in accordance
with the following description taken in conjunction with the
accompanying drawings as follows:
[0004] FIG. 1 illustrates a surgical system comprising a handle and
several shaft assemblies--each of which are selectively attachable
to the handle in accordance with at least one embodiment;
[0005] FIG. 2 is an elevational view of the handle and one of the
shaft assemblies of the surgical system of FIG. 1;
[0006] FIG. 3 is a partial cross-sectional perspective view of the
shaft assembly of FIG. 2;
[0007] FIG. 4 is another partial cross-sectional perspective view
of the shaft assembly of FIG. 2;
[0008] FIG. 5 is a partial exploded view of the shaft assembly of
FIG. 2;
[0009] FIG. 6 is a partial cross-sectional elevational view of the
shaft assembly of FIG. 2;
[0010] FIG. 7 is an elevational view of a drive module of the
handle of FIG. 1;
[0011] FIG. 8 is a cross-sectional perspective view of the drive
module of FIG. 7;
[0012] FIG. 9 is an end view of the drive module of FIG. 7;
[0013] FIG. 10 is a partial cross-sectional view of the
interconnection between the handle and shaft assembly of FIG. 2 in
a locked configuration;
[0014] FIG. 11 is a partial cross-sectional view of the
interconnection between the handle and shaft assembly of FIG. 2 in
an unlocked configuration;
[0015] FIG. 12 is a cross-sectional perspective view of a motor and
a speed reduction gear assembly of the drive module of FIG. 7;
[0016] FIG. 13 is an end view of the speed reduction gear assembly
of FIG. 12;
[0017] FIG. 14 is a partial perspective view of an end effector of
the shaft assembly of FIG. 2 in an open configuration;
[0018] FIG. 15 is a partial perspective view of the end effector of
FIG. 14 in a closed configuration;
[0019] FIG. 16 is a partial perspective view of the end effector of
FIG. 14 articulated in a first direction;
[0020] FIG. 17 is a partial perspective view of the end effector of
FIG. 14 articulated in a second direction;
[0021] FIG. 18 is a partial perspective view of the end effector of
FIG. 14 rotated in a first direction;
[0022] FIG. 19 is a partial perspective view of the end effector of
FIG. 14 rotated in a second direction;
[0023] FIG. 20 is a partial cross-sectional perspective view of the
end effector of FIG. 14 detached from the shaft assembly of FIG.
2;
[0024] FIG. 21 is an exploded view of the end effector of FIG. 14
illustrated with some components removed;
[0025] FIG. 22 is an exploded view of a distal attachment portion
of the shaft assembly of FIG. 2;
[0026] FIG. 22A is an exploded view of the distal portion of the
shaft assembly of FIG. 2 illustrated with some components
removed;
[0027] FIG. 23 is another partial cross-sectional perspective view
of the end effector of FIG. 14 detached from the shaft assembly of
FIG. 2;
[0028] FIG. 24 is a partial cross-sectional perspective view of the
end effector of FIG. 14 attached to the shaft assembly of FIG.
2;
[0029] FIG. 25 is a partial cross-sectional perspective view of the
end effector of FIG. 14 attached to the shaft assembly of FIG.
2;
[0030] FIG. 26 is another partial cross-sectional perspective view
of the end effector of FIG. 14 attached to the shaft assembly of
FIG. 2;
[0031] FIG. 27 is a partial cross-sectional view of the end
effector of FIG. 14 attached to the shaft assembly of FIG. 2
depicting a first, second, and third clutch of the end
effector;
[0032] FIG. 28 depicts the first clutch of FIG. 27 in an unactuated
condition;
[0033] FIG. 29 depicts the first clutch of FIG. 27 in an actuated
condition;
[0034] FIG. 30 depicts the second clutch of FIG. 27 in an
unactuated condition;
[0035] FIG. 31 depicts the second clutch of FIG. 27 in an actuated
condition;
[0036] FIG. 32 depicts the third clutch of FIG. 27 in an unactuated
condition;
[0037] FIG. 33 depicts the third clutch of FIG. 27 in an actuated
condition;
[0038] FIG. 34 depicts the second and third clutches of FIG. 27 in
their unactuated conditions and the end effector of FIG. 14 locked
to the shaft assembly of FIG. 2;
[0039] FIG. 35 depicts the second clutch of FIG. 27 in its
unactuated condition and the third clutch of FIG. 27 in its
actuated condition;
[0040] FIG. 36 depicts the second and third clutches of FIG. 27 in
their actuated conditions and the end effector of FIG. 14 unlocked
from the shaft assembly of FIG. 2;
[0041] FIG. 37 is a partial cross-sectional view of a shaft
assembly in accordance with at least one alternative embodiment
comprising sensors configured to detect the conditions of the
first, second, and third clutches of FIG. 27;
[0042] FIG. 38 is a partial cross-sectional view of a shaft
assembly in accordance with at least one alternative embodiment
comprising sensors configured to detect the conditions of the
first, second, and third clutches of FIG. 27;
[0043] FIG. 39 depicts the first and second clutches of FIG. 38 in
their unactuated conditions and a sensor in accordance with at
least one alternative embodiment;
[0044] FIG. 40 depicts the second and third clutches of FIG. 38 in
their unactuated conditions and a sensor in accordance with at
least one alternative embodiment;
[0045] FIG. 41 is a partial cross-sectional view of a shaft
assembly in accordance with at least one embodiment;
[0046] FIG. 42 is a partial cross-sectional view of the shaft
assembly of FIG. 41 comprising a clutch illustrated in an
unactuated condition;
[0047] FIG. 43 is a partial cross-sectional view of the shaft
assembly of FIG. 41 illustrating the clutch in an actuated
condition;
[0048] FIG. 44 is a partial cross-sectional view of a shaft
assembly in accordance with at least one embodiment comprising
first and second clutches illustrated in an unactuated
condition;
[0049] FIG. 45 is a perspective view of the handle drive module of
FIG. 7 and one of the shaft assemblies of the surgical system of
FIG. 1;
[0050] FIG. 46 is another perspective view of the handle drive
module of FIG. 7 and the shaft assembly of FIG. 45;
[0051] FIG. 47 is a partial cross-sectional view of the shaft
assembly of FIG. 45 attached to the handle of FIG. 1;
[0052] FIG. 48 is another partial cross-sectional view of the shaft
assembly of FIG. 45 attached to the handle of FIG. 1;
[0053] FIG. 49 is a partial cross-sectional perspective view of the
shaft assembly of FIG. 45;
[0054] FIG. 50 is a schematic of the control system of the surgical
system of FIG. 1.
[0055] FIG. 51 is an elevational view of a handle in accordance
with at least one embodiment and one of the shaft assemblies of the
surgical system of FIG. 1;
[0056] FIG. 52A is a partial top view of a drive module of the
handle of FIG. 51 illustrated in a first rotation
configuration;
[0057] FIG. 52B is a partial top view of the drive module of FIG.
52A illustrated in a second rotation configuration;
[0058] FIG. 53A is a partial top view of the drive module of FIG.
52A illustrated in a first articulation configuration;
[0059] FIG. 53B is a partial top view of the drive module of FIG.
52A illustrated in a second articulation configuration;
[0060] FIG. 54 is a partial cross-sectional perspective view of a
drive module in accordance with at least one embodiment;
[0061] FIG. 55 is a partial perspective view of the drive module of
FIG. 54 illustrated with some components removed;
[0062] FIG. 56 is a partial cross-sectional view of the drive
module of FIG. 54 illustrating an eccentric drive in a disengaged
condition; and
[0063] FIG. 57 is a partial cross-sectional view of the drive
module of FIG. 54 illustrating the eccentric drive of FIG. 56 in an
engaged condition.
[0064] FIG. 58 illustrates a surgical instrument system comprising
a handle and several shaft assemblies--each of which are
selectively attachable to the handle in accordance with at least
one embodiment;
[0065] FIG. 59 is an elevational view of the handle and one of the
shaft assemblies of the surgical instrument system of FIG. 58;
[0066] FIG. 60 is an elevational view of a drive module of the
handle of FIG. 58;
[0067] FIG. 61 is a cross-sectional perspective view of the drive
module of FIG. 60;
[0068] FIG. 62 is an end view of the drive module of FIG. 60;
[0069] FIG. 63 is a perspective view of the handle drive module of
FIG. 60 and one of the shaft assemblies of the surgical instrument
system of FIG. 58;
[0070] FIG. 64 is another perspective view of the handle drive
module of FIG. 58 and the shaft assembly of FIG. 63;
[0071] FIG. 65 is a partial cross-sectional perspective view of a
handle drive module in accordance with at least one embodiment;
[0072] FIG. 66 illustrates a surgical instrument system comprising
several handle assemblies and a shaft assembly selectively
attachable to the handle assemblies in accordance with at least one
embodiment;
[0073] FIG. 66A is an elevational view of a handle assembly of FIG.
66 in accordance with at least one embodiment;
[0074] FIG. 66B is an elevational view of a handle assembly of FIG.
66 in accordance with at least one embodiment;
[0075] FIG. 66C is an elevational view of a handle assembly of FIG.
66 in accordance with at least one embodiment;
[0076] FIG. 66D is an elevational view of a handle assembly and the
shaft assembly of FIG. 66 in accordance with at least one
embodiment;
[0077] FIG. 66E is an elevational view of the handle assembly of
FIG. 66B attached to the shaft assembly of FIG. 66 in accordance
with at least one embodiment;
[0078] FIG. 66F is an elevational view of the handle assembly of
FIG. 66B and the shaft assembly of FIG. 66 in accordance with at
least one embodiment;
[0079] FIG. 66G is an elevational view of the handle assembly of
FIG. 66C and the shaft assembly of FIG. 66 in accordance with at
least one embodiment;
[0080] FIG. 67 is a perspective view of the shaft assembly of FIG.
66;
[0081] FIG. 68A is a proximal end view of the handle assembly of
FIG. 66A;
[0082] FIG. 68B is a proximal end view of the handle assembly of
FIG. 66B;
[0083] FIG. 68C is a proximal end view of the handle assembly of
FIG. 66C;
[0084] FIG. 68D is a proximal end view of the shaft assembly of
FIG. 66D;
[0085] FIG. 69 illustrates a chart depicting various functions of
the surgical instrument system of FIG. 66;
[0086] FIG. 70 is an exploded view of one of the handle assemblies
and the shaft assembly of FIG. 66;
[0087] FIG. 71 depicts various aspects of the handle assembly of
FIG. 70;
[0088] FIG. 72 is an exploded view of the handle assembly of FIG.
66B and the shaft assembly of FIG. 66;
[0089] FIG. 73 depicts various aspects of the handle assembly of
FIG. 72;
[0090] FIG. 73A is a proximal end view of the handle assembly of
FIG. 72;
[0091] FIG. 73B illustrates a chart depicting various functions of
the handle assembly of FIG. 72;
[0092] FIG. 74 is a partial exploded view the handle assembly of
FIG. 66A and the shaft assembly of FIG. 66;
[0093] FIG. 75 depicts various aspects of the handle assembly of
FIG. 74;
[0094] FIG. 75A is a proximal end view of the handle assembly of
FIG. 74;
[0095] FIG. 75B illustrates a chart depicting various functions of
the handle assembly of FIG. 74;
[0096] FIG. 76 illustrates a shaft assembly in accordance with at
least one embodiment;
[0097] FIG. 76A is a block diagram illustrating the electrical
connections of a surgical instrument system in accordance with at
least one embodiment;
[0098] FIG. 77 illustrates a surgical system comprising a handle
and a shaft assembly in accordance with at least one
embodiment;
[0099] FIG. 77A is a perspective view of the handle assembly of
FIG. 77;
[0100] FIG. 77B is a cut-away view of a curved cylinder of the
handle assembly of FIG. 77;
[0101] FIG. 78A is a partial cross-sectional view of the curved
cylinder of FIG. 77A illustrating an electroactive polymer located
in the cylinder in a non-energized state;
[0102] FIG. 78B is a partial cross-sectional view of the curved
cylinder of FIG. 77A illustrating the electroactive polymer located
in the cylinder in an energized state;
[0103] FIG. 79 is a block diagram illustrating various aspects of
the handle and shaft assembly of FIG. 77 in accordance with at
least one embodiment;
[0104] FIG. 80 is a graph illustrating the relationship between the
forces experienced by an end effector and shaft of the surgical
system of FIG. 77 and the voltage applied to the electroactive
polymer over time;
[0105] FIG. 81 is a graph illustrating the compressive force
applied by the electroactive polymer over time;
[0106] FIG. 82 illustrates a surgical system comprising a handle
and a shaft assembly in accordance with at least one
embodiment;
[0107] FIG. 83 is a partial perspective view of the shaft assembly
of FIG. 82 comprising a locking mechanism;
[0108] FIG. 84 is a perspective view of the locking mechanism of
FIG. 83 in an unlocked configuration;
[0109] FIG. 85 is a perspective view of the locking mechanism of
FIG. 83 in a locked configuration;
[0110] FIGS. 85A-85C illustrate the locking mechanism of FIG. 83 in
three different states during the operation of the surgical
instrument system;
[0111] FIG. 86 is a partial perspective view of a distal attachment
portion selectively attachable to the surgical system of FIG.
82;
[0112] FIG. 87 is a graph illustrating possible drive force curves
of the distal attachment portion of FIG. 86; and
[0113] FIG. 88 is a flow chart illustrating a start-up process of a
surgical instrument system in accordance with at least one
embodiment.
[0114] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplifications set out
herein illustrate various embodiments of the invention, in one
form, and such exemplifications are not to be construed as limiting
the scope of the invention in any manner.
DETAILED DESCRIPTION
[0115] Applicant of the present application owns the following U.S.
patent applications that were filed on even date herewith and which
are each herein incorporated by reference in their respective
entireties:
[0116] U.S. patent application Ser. No. ______, entitled SURGICAL
SUTURING INSTRUMENT CONFIGURED TO MANIPULATE TISSUE USING
MECHANICAL AND ELECTRICAL POWER; Attorney Docket No.
END8567USNP1/180100-1;
[0117] U.S. patent application Ser. No. ______, entitled SURGICAL
SUTURING INSTRUMENT COMPRISING A CAPTURE WIDTH WHICH IS LARGER THAN
TROCAR DIAMETER; Attorney Docket No. END8567USNP2/180100-2;
[0118] U.S. patent application Ser. No. ______, entitled SURGICAL
SUTURING INSTRUMENT COMPRISING A NON-CIRCULAR NEEDLE; Attorney
Docket No. END8567USNP3/180100-3;
[0119] U.S. patent application Ser. No. ______, entitled ELECTRICAL
POWER OUTPUT CONTROL BASED ON MECHANICAL FORCES; Attorney Docket
No. END8567USNP4/180100-4;
[0120] U.S. patent application Ser. No. ______, entitled REACTIVE
ALGORITHM FOR SURGICAL SYSTEM; Attorney Docket No.
END8567USNP5/180100-5;
[0121] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT COMPRISING AN ADAPTIVE ELECTRICAL SYSTEM; Attorney
Docket No. END8568USNP1/180101-1;
[0122] U.S. patent application Ser. No. ______, entitled CONTROL
SYSTEM ARRANGEMENTS FOR A MODULAR SURGICAL INSTRUMENT; Attorney
Docket No. END8568USNP2/180101-2;
[0123] U.S. patent application Ser. No. ______, entitled ADAPTIVE
CONTROL PROGRAMS FOR A SURGICAL SYSTEM COMPRISING MORE THAN ONE
TYPE OF CARTRIDGE; Attorney Docket No. END8568USNP3/180101-3;
[0124] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT SYSTEMS COMPRISING BATTERY ARRANGEMENTS; Attorney Docket
No. END8569USNP1/180102-1;
[0125] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT SYSTEMS COMPRISING HANDLE ARRANGEMENTS; Attorney Docket
No. END8569USNP2/180102-2;
[0126] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENT SYSTEMS COMPRISING FEEDBACK MECHANISMS; Attorney Docket
No. END8569USNP3/180102-3;
[0127] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENTS COMPRISING A LOCKABLE END EFFECTOR SOCKET; Attorney
Docket No. END8570USNP1/180103-1;
[0128] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENTS COMPRISING A SHIFTING MECHANISM; Attorney Docket No.
END8570USNP2/180103-2;
[0129] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENTS COMPRISING A SYSTEM FOR ARTICULATION AND ROTATION
COMPENSATION; Attorney Docket No. END8570USNP3/180103-3;
[0130] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENTS COMPRISING A BIASED SHIFTING MECHANISM; Attorney Docket
No. END8570USNP4/180103-4;
[0131] U.S. patent application Ser. No. ______, entitled SURGICAL
INSTRUMENTS COMPRISING AN ARTICULATION DRIVE THAT PROVIDES FOR HIGH
ARTICULATION ANGLES; Attorney Docket No. END8570USNP5/180103-5;
[0132] U.S. patent application Ser. No. ______, entitled SURGICAL
DISSECTORS AND MANUFACTURING TECHNIQUES; Attorney Docket No.
END8571USNP1/180104-1;
[0133] U.S. patent application Ser. No. ______, entitled SURGICAL
DISSECTORS CONFIGURED TO APPLY MECHANICAL AND ELECTRICAL ENERGY;
Attorney Docket No. END8571USNP2/180104-2;
[0134] U.S. patent application Ser. No. ______, entitled SURGICAL
CLIP APPLIER CONFIGURED TO STORE CLIPS IN A STORED STATE; Attorney
Docket No. END8572USNP1/180105-1;
[0135] U.S. patent application Ser. No. ______, entitled SURGICAL
CLIP APPLIER COMPRISING AN EMPTY CLIP CARTRIDGE LOCKOUT; Attorney
Docket No. END8572USNP2/180105-2;
[0136] U.S. patent application Ser. No. ______, entitled SURGICAL
CLIP APPLIER COMPRISING AN AUTOMATIC CLIP FEEDING SYSTEM; Attorney
Docket No. END8572USNP3/180105-3;
[0137] U.S. patent application Ser. No. ______, entitled SURGICAL
CLIP APPLIER COMPRISING ADAPTIVE FIRING CONTROL; Attorney Docket
No. END8572USNP4/180105-4; and
[0138] U.S. patent application Ser. No. ______, entitled SURGICAL
CLIP APPLIER COMPRISING ADAPTIVE CONTROL IN RESPONSE TO A STRAIN
GAUGE CIRCUIT; Attorney Docket No. END8572USNP5/180105-5.
[0139] Applicant of the present application owns the following U.S.
patent applications that were filed on May 1, 2018 and which are
each herein incorporated by reference in their respective
entireties:
[0140] U.S. Patent Application Ser. No. 62/665,129, entitled
SURGICAL SUTURING SYSTEMS;
[0141] U.S. Provisional Patent Application Ser. No. 62/665,139,
entitled SURGICAL INSTRUMENTS COMPRISING CONTROL SYSTEMS;
[0142] U.S. Patent Application Ser. No. 62/665,177, entitled
SURGICAL INSTRUMENTS COMPRISING HANDLE ARRANGEMENTS;
[0143] U.S. Patent Application Ser. No. 62/665,128, entitled
MODULAR SURGICAL INSTRUMENTS;
[0144] U.S. Patent Application Ser. No. 62/665,192, entitled
SURGICAL DISSECTORS; and
[0145] U.S. Patent Application Ser. No. 62/665,134, entitled
SURGICAL CLIP APPLIER.
[0146] Applicant of the present application owns the following U.S.
patent applications that were filed on Feb. 28, 2018 and which are
each herein incorporated by reference in their respective
entireties:
[0147] U.S. patent application Ser. No. 15/908,021, entitled
SURGICAL INSTRUMENT WITH REMOTE RELEASE;
[0148] U.S. patent application Ser. No. 15/908,012, entitled
SURGICAL INSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO EFFECT
DIFFERENT TYPES OF END EFFECTOR MOVEMENT;
[0149] U.S. patent application Ser. No. 15/908,040, entitled
SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING
MULTIPLE END EFFECTOR FUNCTIONS;
[0150] U.S. patent application Ser. No. 15/908,057, entitled
SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY ACTUATING
MULTIPLE END EFFECTOR FUNCTIONS;
[0151] U.S. patent application Ser. No. 15/908,058, entitled
SURGICAL INSTRUMENT WITH MODULAR POWER SOURCES; and
[0152] U.S. patent application Ser. No. 15/908,143, entitled
SURGICAL INSTRUMENT WITH SENSOR AND/OR CONTROL SYSTEMS.
[0153] Applicant of the present application owns the following U.S.
patent applications that were filed on Oct. 30, 2017 and which are
each herein incorporated by reference in their respective
entireties:
[0154] U.S. Provisional Patent Application Ser. No. 62/578,793,
entitled SURGICAL INSTRUMENT WITH REMOTE RELEASE;
[0155] U.S. Provisional Patent Application Ser. No. 62/578,804,
entitled SURGICAL INSTRUMENT HAVING DUAL ROTATABLE MEMBERS TO
EFFECT DIFFERENT TYPES OF END EFFECTOR MOVEMENT;
[0156] U.S. Provisional Patent Application Ser. No. 62/578,817,
entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY
ACTUATING MULTIPLE END EFFECTOR FUNCTIONS;
[0157] U.S. Provisional Patent Application Ser. No. 62/578,835,
entitled SURGICAL INSTRUMENT WITH ROTARY DRIVE SELECTIVELY
ACTUATING MULTIPLE END EFFECTOR FUNCTIONS;
[0158] U.S. Provisional Patent Application Ser. No. 62/578,844,
entitled SURGICAL INSTRUMENT WITH MODULAR POWER SOURCES; and
[0159] U.S. Provisional Patent Application Ser. No. 62/578,855,
entitled SURGICAL INSTRUMENT WITH SENSOR AND/OR CONTROL
SYSTEMS.
[0160] Applicant of the present application owns the following U.S.
Provisional Patent Applications, filed on Dec. 28, 2017, the
disclosure of each of which is herein incorporated by reference in
its entirety:
[0161] U.S. Provisional Patent Application Ser. No. 62/611,341,
entitled INTERACTIVE SURGICAL PLATFORM;
[0162] U.S. Provisional Patent Application Ser. No. 62/611,340,
entitled CLOUD-BASED MEDICAL ANALYTICS; and
[0163] U.S. Provisional Patent Application Ser. No. 62/611,339,
entitled ROBOT ASSISTED SURGICAL PLATFORM.
[0164] Applicant of the present application owns the following U.S.
Provisional Patent Applications, filed on Mar. 28, 2018, each of
which is herein incorporated by reference in its entirety:
[0165] U.S. Provisional Patent Application Ser. No. 62/649,302,
entitled INTERACTIVE SURGICAL SYSTEMS WITH ENCRYPTED COMMUNICATION
CAPABILITIES;
[0166] U.S. Provisional Patent Application Ser. No. 62/649,294,
entitled DATA STRIPPING METHOD TO INTERROGATE PATIENT RECORDS AND
CREATE ANONYMIZED RECORD;
[0167] U.S. Provisional Patent Application Ser. No. 62/649,300,
entitled SURGICAL HUB SITUATIONAL AWARENESS;
[0168] U.S. Provisional Patent Application Ser. No. 62/649,309,
entitled SURGICAL HUB SPATIAL AWARENESS TO DETERMINE DEVICES IN
OPERATING THEATER;
[0169] U.S. Provisional Patent Application Ser. No. 62/649,310,
entitled COMPUTER IMPLEMENTED INTERACTIVE SURGICAL SYSTEMS;
[0170] U.S. Provisional Patent Application Ser. No. 62/649,291,
entitled USE OF LASER LIGHT AND RED-GREEN-BLUE COLORATION TO
DETERMINE PROPERTIES OF BACK SCATTERED LIGHT;
[0171] U.S. Provisional Patent Application Ser. No. 62/649,296,
entitled ADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICAL DEVICES;
[0172] U.S. Provisional Patent Application Ser. No. 62/649,333,
entitled CLOUD-BASED MEDICAL ANALYTICS FOR CUSTOMIZATION AND
RECOMMENDATIONS TO A USER;
[0173] U.S. Provisional Patent Application Ser. No. 62/649,327,
entitled CLOUD-BASED MEDICAL ANALYTICS FOR SECURITY AND
AUTHENTICATION TRENDS AND REACTIVE MEASURES;
[0174] U.S. Provisional Patent Application Ser. No. 62/649,315,
entitled DATA HANDLING AND PRIORITIZATION IN A CLOUD ANALYTICS
NETWORK;
[0175] U.S. Provisional Patent Application Ser. No. 62/649,313,
entitled CLOUD INTERFACE FOR COUPLED SURGICAL DEVICES;
[0176] U.S. Provisional Patent Application Ser. No. 62/649,320,
entitled DRIVE ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL
PLATFORMS;
[0177] U.S. Provisional Patent Application Ser. No. 62/649,307,
entitled AUTOMATIC TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL
PLATFORMS; and
[0178] U.S. Provisional Patent Application Ser. No. 62/649,323,
entitled SENSING ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL
PLATFORMS.
[0179] Applicant of the present application owns the following U.S.
patent applications, filed on Mar. 29, 2018, each of which is
herein incorporated by reference in its entirety:
[0180] U.S. patent application Ser. No. 15/940,641, entitled
INTERACTIVE SURGICAL SYSTEMS WITH ENCRYPTED COMMUNICATION
CAPABILITIES;
[0181] U.S. patent application Ser. No. 15/940,648, entitled
INTERACTIVE SURGICAL SYSTEMS WITH CONDITION HANDLING OF DEVICES AND
DATA CAPABILITIES;
[0182] U.S. patent application Ser. No. 15/940,656, entitled
SURGICAL HUB COORDINATION OF CONTROL AND COMMUNICATION OF OPERATING
ROOM DEVICES;
[0183] U.S. patent application Ser. No. 15/940,666, entitled
SPATIAL AWARENESS OF SURGICAL HUBS IN OPERATING ROOMS;
[0184] U.S. patent application Ser. No. 15/940,670, entitled
COOPERATIVE UTILIZATION OF DATA DERIVED FROM SECONDARY SOURCES BY
INTELLIGENT SURGICAL HUBS;
[0185] U.S. patent application Ser. No. 15/940,677, entitled
SURGICAL HUB CONTROL ARRANGEMENTS;
[0186] U.S. patent application Ser. No. 15/940,632, entitled DATA
STRIPPING METHOD TO INTERROGATE PATIENT RECORDS AND CREATE
ANONYMIZED RECORD;
[0187] U.S. patent application Ser. No. 15/940,640, entitled
COMMUNICATION HUB AND STORAGE DEVICE FOR STORING PARAMETERS AND
STATUS OF A SURGICAL DEVICE TO BE SHARED WITH CLOUD BASED ANALYTICS
SYSTEMS;
[0188] U.S. patent application Ser. No. 15/940,645, entitled SELF
DESCRIBING DATA PACKETS GENERATED AT AN ISSUING INSTRUMENT;
[0189] U.S. patent application Ser. No. 15/940,649, entitled DATA
PAIRING TO INTERCONNECT A DEVICE MEASURED PARAMETER WITH AN
OUTCOME;
[0190] U.S. patent application Ser. No. 15/940,654, entitled
SURGICAL HUB SITUATIONAL AWARENESS;
[0191] U.S. patent application Ser. No. 15/940,663, entitled
SURGICAL SYSTEM DISTRIBUTED PROCESSING;
[0192] U.S. patent application Ser. No. 15/940,668, entitled
AGGREGATION AND REPORTING OF SURGICAL HUB DATA;
[0193] U.S. patent application Ser. No. 15/940,671, entitled
SURGICAL HUB SPATIAL AWARENESS TO DETERMINE DEVICES IN OPERATING
THEATER;
[0194] U.S. patent application Ser. No. 15/940,686, entitled
DISPLAY OF ALIGNMENT OF STAPLE CARTRIDGE TO PRIOR LINEAR STAPLE
LINE;
[0195] U.S. patent application Ser. No. 15/940,700, entitled
STERILE FIELD INTERACTIVE CONTROL DISPLAYS;
[0196] U.S. patent application Ser. No. 15/940,629, entitled
COMPUTER IMPLEMENTED INTERACTIVE SURGICAL SYSTEMS;
[0197] U.S. patent application Ser. No. 15/940,704, entitled USE OF
LASER LIGHT AND RED-GREEN-BLUE COLORATION TO DETERMINE PROPERTIES
OF BACK SCATTERED LIGHT;
[0198] U.S. patent application Ser. No. 15/940,722, entitled
CHARACTERIZATION OF TISSUE IRREGULARITIES THROUGH THE USE OF
MONO-CHROMATIC LIGHT REFRACTIVITY; and
[0199] U.S. patent application Ser. No. 15/940,742, entitled DUAL
CMOS ARRAY IMAGING.
[0200] Applicant of the present application owns the following U.S.
patent applications, filed on Mar. 29, 2018, each of which is
herein incorporated by reference in its entirety:
[0201] U.S. patent application Ser. No. 15/940,636, entitled
ADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICAL DEVICES;
[0202] U.S. patent application Ser. No. 15/940,653, entitled
ADAPTIVE CONTROL PROGRAM UPDATES FOR SURGICAL HUBS;
[0203] U.S. patent application Ser. No. 15/940,660, entitled
CLOUD-BASED MEDICAL ANALYTICS FOR CUSTOMIZATION AND RECOMMENDATIONS
TO A USER;
[0204] U.S. patent application Ser. No. 15/940,679, entitled
CLOUD-BASED MEDICAL ANALYTICS FOR LINKING OF LOCAL USAGE TRENDS
WITH THE RESOURCE ACQUISITION BEHAVIORS OF LARGER DATA SET;
[0205] U.S. patent application Ser. No. 15/940,694, entitled
CLOUD-BASED MEDICAL ANALYTICS FOR MEDICAL FACILITY SEGMENTED
INDIVIDUALIZATION OF INSTRUMENT FUNCTION;
[0206] U.S. patent application Ser. No. 15/940,634, entitled
CLOUD-BASED MEDICAL ANALYTICS FOR SECURITY AND AUTHENTICATION
TRENDS AND REACTIVE MEASURES;
[0207] U.S. patent application Ser. No. 15/940,706, entitled DATA
HANDLING AND PRIORITIZATION IN A CLOUD ANALYTICS NETWORK; and
[0208] U.S. patent application Ser. No. 15/940,675, entitled CLOUD
INTERFACE FOR COUPLED SURGICAL DEVICES.
[0209] Applicant of the present application owns the following U.S.
patent applications, filed on Mar. 29, 2018, each of which is
herein incorporated by reference in its entirety:
[0210] U.S. patent application Ser. No. 15/940,627, entitled DRIVE
ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;
[0211] U.S. patent application Ser. No. 15/940,637, entitled
COMMUNICATION ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL
PLATFORMS;
[0212] U.S. patent application Ser. No. 15/940,642, entitled
CONTROLS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;
[0213] U.S. patent application Ser. No. 15/940,676, entitled
AUTOMATIC TOOL ADJUSTMENTS FOR ROBOT-ASSISTED SURGICAL
PLATFORMS;
[0214] U.S. patent application Ser. No. 15/940,680, entitled
CONTROLLERS FOR ROBOT-ASSISTED SURGICAL PLATFORMS;
[0215] U.S. patent application Ser. No. 15/940,683, entitled
COOPERATIVE SURGICAL ACTIONS FOR ROBOT-ASSISTED SURGICAL
PLATFORMS;
[0216] U.S. patent application Ser. No. 15/940,690, entitled
DISPLAY ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS; and
[0217] U.S. patent application Ser. No. 15/940,711, entitled
SENSING ARRANGEMENTS FOR ROBOT-ASSISTED SURGICAL PLATFORMS.
[0218] Applicant of the present application owns the following U.S.
Provisional Patent Applications, filed on Mar. 30, 2018, each of
which is herein incorporated by reference in its entirety:
[0219] U.S. Provisional Patent Application Ser. No. 62/650,887,
entitled SURGICAL SYSTEMS WITH OPTIMIZED SENSING CAPABILITIES;
[0220] U.S. Provisional Patent Application Ser. No. 62/650,877,
entitled SURGICAL SMOKE EVACUATION SENSING AND CONTROLS;
[0221] U.S. Provisional Patent Application Ser. No. 62/650,882,
entitled SMOKE EVACUATION MODULE FOR INTERACTIVE SURGICAL PLATFORM;
and
[0222] U.S. Provisional Patent Application Ser. No. 62/650,898,
entitled CAPACITIVE COUPLED RETURN PATH PAD WITH SEPARABLE ARRAY
ELEMENTS.
[0223] Applicant of the present application owns the following U.S.
Provisional Patent Application, filed on Apr. 19, 2018, which is
herein incorporated by reference in its entirety:
[0224] U.S. Provisional Patent Application Ser. No. 62/659,900,
entitled METHOD OF HUB COMMUNICATION.
[0225] Numerous specific details are set forth to provide a
thorough understanding of the overall structure, function,
manufacture, and use of the embodiments as described in the
specification and illustrated in the accompanying drawings.
Well-known operations, components, and elements have not been
described in detail so as not to obscure the embodiments described
in the specification. The reader will understand that the
embodiments described and illustrated herein are non-limiting
examples, and thus it can be appreciated that the specific
structural and functional details disclosed herein may be
representative and illustrative. Variations and changes thereto may
be made without departing from the scope of the claims.
[0226] The terms "comprise" (and any form of comprise, such as
"comprises" and "comprising"), "have" (and any form of have, such
as "has" and "having"), "include" (and any form of include, such as
"includes" and "including"), and "contain" (and any form of
contain, such as "contains" and "containing") are open-ended
linking verbs. As a result, a surgical system, device, or apparatus
that "comprises," "has," "includes", or "contains" one or more
elements possesses those one or more elements, but is not limited
to possessing only those one or more elements. Likewise, an element
of a system, device, or apparatus that "comprises," "has,"
"includes", or "contains" one or more features possesses those one
or more features, but is not limited to possessing only those one
or more features.
[0227] The terms "proximal" and "distal" are used herein with
reference to a clinician manipulating the handle portion of the
surgical instrument. The term "proximal" refers to the portion
closest to the clinician and the term "distal" refers 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.
[0228] Various exemplary devices and methods are provided for
performing laparoscopic and minimally invasive surgical procedures.
However, the reader 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, the reader 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 elongate
shaft of a surgical instrument can be advanced.
[0229] A surgical instrument, such as a grasper, for example, can
comprise a handle, a shaft extending from the handle, and an end
effector extending from the shaft. In various instances, the end
effector comprises a first jaw and a second jaw, wherein one or
both of the jaws are movable relative to the other to grasp the
tissue of a patient. That said, an end effector of a surgical
instrument can comprise any suitable arrangement and can perform
any suitable function. For instance, an end effector can comprise
first and second jaws configured to dissect or separate the tissue
of a patient. Also, for instance, an end effector can be configured
to suture and/or clip the tissue of a patient. In various
instances, the end effector and/or shaft of the surgical instrument
are configured to be inserted into a patient through a trocar, or
cannula, and can have any suitable diameter, such as approximately
5 mm, 8 mm, and/or 12 mm, for example. U.S. patent application Ser.
No. 11/013,924, entitled TROCAR SEAL ASSEMBLY, now U.S. Pat. No.
7,371,227, is incorporated by reference in its entirety. The shaft
can define a longitudinal axis and at least a portion of the end
effector can be rotatable about the longitudinal axis. Moreover,
the surgical instrument can further comprise an articulation joint
which can permit at least a portion of the end effector to be
articulated relative to the shaft. In use, a clinician can rotate
and/or articulate the end effector in order to maneuver the end
effector within the patient.
[0230] A surgical instrument system is depicted in FIG. 1. The
surgical instrument system comprises a handle assembly 1000 which
is selectively usable with a shaft assembly 2000, a shaft assembly
3000, a shaft assembly 4000, a shaft assembly 5000, and/or any
other suitable shaft assembly. The shaft assembly 2000 is attached
to the handle assembly 1000 in FIG. 2 and the shaft assembly 4000
is attached to the handle assembly 1000 in FIG. 45. The shaft
assembly 2000 comprises a proximal portion 2100, an elongate shaft
2200 extending from the proximal portion 2100, a distal attachment
portion 2400, and an articulation joint 2300 rotatably connecting
the distal attachment portion 2400 to the elongate shaft 2200. The
shaft assembly 2000 further comprises a replaceable end effector
assembly 7000 attached to the distal attachment portion 2400. The
replaceable end effector assembly 7000 comprises a jaw assembly
7100 configured to be opened and closed to clamp and/or manipulate
the tissue of a patient. In use, the end effector assembly 7000 can
be articulated about the articulation joint 2300 and/or rotated
relative to the distal attachment portion 2400 about a longitudinal
axis to better position the jaw assembly 7100 within the patient,
as described in greater detail further below.
[0231] Referring again to FIG. 1, the handle assembly 1000
comprises, among other things, a drive module 1100. As described in
greater detail below, the drive module 1100 comprises a distal
mounting interface which permits a clinician to selectively attach
one of the shaft assemblies 2000, 3000, 4000, and 5000, for
example, to the drive module 1100. Thus, each of the shaft
assemblies 2000, 3000, 4000, and 5000 comprises an identical, or an
at least similar, proximal mounting interface which is configured
to engage the distal mounting interface of the drive module 1100.
As also described in greater detail below, the mounting interface
of the drive module 1100 mechanically secures and electrically
couples the selected shaft assembly to the drive module 1100. The
drive module 1100 further comprises at least one electric motor,
one or more controls and/or displays, and a controller configured
to operate the electric motor--the rotational output of which is
transmitted to a drive system of the shaft assembly attached to the
drive module 1100. Moreover, the drive module 1100 is usable with
one ore more power modules, such as power modules 1200 and 1300,
for example, which are operably attachable to the drive module 1100
to supply power thereto.
[0232] Further to the above, referring again to FIGS. 1 and 2, the
handle drive module 1100 comprises a housing 1110, a first module
connector 1120, and a second module connector 1120'. The power
module 1200 comprises a housing 1210, a connector 1220, one or more
release latches 1250, and one or more batteries 1230. The connector
1220 is configured to be engaged with the first module connector
1120 of the drive module 1100 in order to attach the power module
1200 to the drive module 1100. The connector 1220 comprises one or
more latches 1240 which mechanically couple and fixedly secure the
housing 1210 of the power module 1200 to the housing 1110 of the
drive module 1100. The latches 1240 are movable into disengaged
positions when the release latches 1250 are depressed so that the
power module 1200 can be detached from the drive module 1100. The
connector 1220 also comprises one or more electrical contacts which
place the batteries 1230, and/or an electrical circuit including
the batteries 1230, in electrical communication with an electrical
circuit in the drive module 1100.
[0233] Further to the above, referring again to FIGS. 1 and 2, the
power module 1300 comprises a housing 1310, a connector 1320, one
or more release latches 1350, and one or more batteries 1330 (FIG.
47). The connector 1320 is configured to be engaged with the second
module connector 1120' of the drive module 1100 to attach the power
module 1300 to the drive module 1100. The connector 1320 comprises
one or more latches 1340 which mechanically couple and fixedly
secure the housing 1310 of the power module 1300 to the housing
1110 of the drive module 1100. The latches 1340 are movable into
disengaged positions when the release latches 1350 are depressed so
that the power module 1300 can be detached from the drive module
1100. The connector 1320 also comprises one or more electrical
contacts which place the batteries 1330 of the power module 1300,
and/or an electrical power circuit including the batteries 1330, in
electrical communication with an electrical power circuit in the
drive module 1100.
[0234] Further to the above, the power module 1200, when attached
to the drive module 1100, comprises a pistol grip which can allow a
clinician to hold the handle 1000 in a manner which places the
drive module 1100 on top of the clinician's hand. The power module
1300, when attached to the drive module 1100, comprises an end grip
which allows a clinician to hold the handle 1000 like a wand. The
power module 1200 is longer than the power module 1300, although
the power modules 1200 and 1300 can comprise any suitable length.
The power module 1200 has more battery cells than the power module
1300 and can suitably accommodate these additional battery cells
owing to its length. In various instances, the power module 1200
can provide more power to the drive module 1100 than the power
module 1300 while, in some instances, the power module 1200 can
provide power for a longer period of time. In some instances, the
housing 1110 of the drive module 1100 comprises keys, and/or any
other suitable features, which prevent the power module 1200 from
being connected to the second module connector 1120' and,
similarly, prevent the power module 1300 from being connected to
the first module connector 1120. Such an arrangement can assure
that the longer power module 1200 is used in the pistol grip
arrangement and that the shorter power module 1300 is used in the
wand grip arrangement. In alternative embodiments, the power module
1200 and the power module 1300 can be selectively coupled to the
drive module 1100 at either the first module connector 1120 or the
second module connector 1120'. Such embodiments provide a clinician
with more options to customize the handle 1000 in a manner suitable
to them.
[0235] In various instances, further to the above, only one of the
power modules 1200 and 1300 is coupled to the drive module 1100 at
a time. In certain instances, the power module 1200 can be in the
way when the shaft assembly 4000, for example, is attached to the
drive module 1100. Alternatively, both of the power modules 1200
and 1300 can be operably coupled to the drive module 1100 at the
same time. In such instances, the drive module 1100 can have access
to power provided by both of the power modules 1200 and 1300.
Moreover, a clinician can switch between a pistol grip and a wand
grip when both of the power modules 1200 and 1300 are attached to
the drive module 1100. Moreover, such an arrangement allows the
power module 1300 to act as a counterbalance to a shaft assembly,
such as shaft assemblies 2000, 3000, 4000, or 5000, for example,
attached to the drive module 1100.
[0236] Referring to FIGS. 7 and 8, the handle drive module 1100
further comprises a frame 1500, a motor assembly 1600, a drive
system 1700 operably engaged with the motor assembly 1600, and a
control system 1800. The frame 1500 comprises an elongate shaft
that extends through the motor assembly 1600. The elongate shaft
comprises a distal end 1510 and electrical contacts, or sockets,
1520 defined in the distal end 1510. The electrical contacts 1520
are in electrical communication with the control system 1800 of the
drive module 1100 via one or more electrical circuits and are
configured to convey signals and/or power between the control
system 1800 and the shaft assembly, such as the shaft assembly
2000, 3000, 4000, or 5000, for example, attached to the drive
module 1100. The control system 1800 comprises a printed circuit
board (PCB) 1810, at least one microprocessor 1820, and at least
one memory device 1830. The board 1810 can be rigid and/or flexible
and can comprise any suitable number of layers. The microprocessor
1820 and the memory device 1830 are part of a control circuit
defined on the board 1810 which controls the operation of the motor
assembly 1600, as described in greater detail below.
[0237] Referring to FIGS. 12 and 13, the motor assembly 1600
comprises an electric motor 1610 including a housing 1620, a drive
shaft 1630, and a gear reduction system. The electric motor 1610
further comprises a stator including windings 1640 and a rotor
including magnetic elements 1650. The stator windings 1640 are
supported in the housing 1620 and the rotor magnetic elements 1650
are mounted to the drive shaft 1630. When the stator windings 1640
are energized with an electric current controlled by the control
system 1800, the drive shaft 1630 is rotated about a longitudinal
axis. The drive shaft 1630 is operably engaged with a first
planetary gear system 1660 which includes a central sun gear and
several planetary gears operably intermeshed with the sun gear. The
sun gear of the first planetary gear system 1660 is fixedly mounted
to the drive shaft 1630 such that it rotates with the drive shaft
1630. The planetary gears of the first planetary gear system 1660
are rotatably mounted to the sun gear of a second planetary gear
system 1670 and, also, intermeshed with a geared or splined inner
surface 1625 of the motor housing 1620. As a result of the above,
the rotation of the first sun gear rotates the first planetary
gears which rotate the second sun gear. Similar to the above, the
second planetary gear system 1670 further comprises planetary gears
1665 (FIG. 13) which drive a third planetary gear system and,
ultimately, the drive shaft 1710. The planetary gear systems 1660,
1670, and 1680 co-operate to gear down the speed applied to the
drive shaft 1710 by the motor shaft 1620. Various alternative
embodiments are envisioned without a speed reduction system. Such
embodiments are suitable when it is desirable to drive the end
effector functions quickly. Notably, the drive shaft 1630 comprises
an aperture, or hollow core, extending therethrough through which
wires and/or electrical circuits can extend.
[0238] The control system 1800 is in communication with the motor
assembly 1600 and the electrical power circuit of the drive module
1100. The control system 1800 is configured to control the power
delivered to the motor assembly 1600 from the electrical power
circuit. The electrical power circuit is configured to supply a
constant, or at least nearly constant, direct current (DC) voltage.
In at least one instance, the electrical power circuit supplies 3
VDC to the control system 1800. The control system 1800 comprises a
pulse width modulation (PWM) circuit which is configured to deliver
voltage pulses to the motor assembly 1600. The duration or width of
the voltage pulses, and/or the duration or width between the
voltage pulses, supplied by the PWM circuit can be controlled in
order to control the power applied to the motor assembly 1600. By
controlling the power applied to the motor assembly 1600, the PWM
circuit can control the speed of the output shaft of the motor
assembly 1600. In addition to or in lieu of a PWM circuit, the
control system 1800 can include a frequency modulation (FM)
circuit. As discussed in greater detail below, the control system
1800 is operable in more than one operating mode and, depending on
the operating mode being used, the control system 1800 can operate
the motor assembly 1600 at a speed, or a range of speeds, which is
determined to be appropriate for that operating mode.
[0239] Further to the above, referring again to FIGS. 7 and 8, the
drive system 1700 comprises a rotatable shaft 1710 comprising a
splined distal end 1720 and a longitudinal aperture 1730 defined
therein. The rotatable shaft 1710 is operably mounted to the output
shaft of the motor assembly 1600 such that the rotatable shaft 1710
rotates with the motor output shaft. The handle frame 1510 extends
through the longitudinal aperture 1730 and rotatably supports the
rotatable shaft 1710. As a result, the handle frame 1510 serves as
a bearing for the rotatable shaft 1710. The handle frame 1510 and
the rotatable shaft 1710 extend distally from a mounting interface
1130 of the drive module 1110 and are coupled with corresponding
components on the shaft assembly 2000 when the shaft assembly 2000
is assembled to the drive module 1100. Referring primarily to FIGS.
3-6, the shaft assembly 2000 further comprises a frame 2500 and a
drive system 2700. The frame 2500 comprises a longitudinal shaft
2510 extending through the shaft assembly 2000 and a plurality of
electrical contacts, or pins, 2520 extending proximally from the
shaft 2510. When the shaft assembly 2000 is attached to the drive
module 1100, the electrical contacts 2520 on the shaft frame 2510
engage the electrical contacts 1520 on the handle frame 1510 and
create electrical pathways therebetween.
[0240] Similar to the above, the drive system 2700 comprises a
rotatable drive shaft 2710 which is operably coupled to the
rotatable drive shaft 1710 of the handle 1000 when the shaft
assembly 2000 is assembled to the drive module 1100 such that the
drive shaft 2710 rotates with the drive shaft 1710. To this end,
the drive shaft 2710 comprises a splined proximal end 2720 which
mates with the splined distal end 1720 of the drive shaft 1710 such
that the drive shafts 1710 and 2710 rotate together when the drive
shaft 1710 is rotated by the motor assembly 1600. Given the nature
of the splined interconnection between the drive shafts 1710 and
2710 and the electrical interconnection between the frames 1510 and
2510, the shaft assembly 2000 is assembled to the handle 1000 along
a longitudinal axis; however, the operable interconnection between
the drive shafts 1710 and 2710 and the electrical interconnection
between the frames 1510 and 2510 can comprise any suitable
configuration which can allow a shaft assembly to be assembled to
the handle 1000 in any suitable manner.
[0241] As discussed above, referring to FIGS. 3-8, the mounting
interface 1130 of the drive module 1110 is configured to be coupled
to a corresponding mounting interface on the shaft assemblies 2000,
3000, 4000, and 5000, for example. For instance, the shaft assembly
2000 comprises a mounting interface 2130 configured to be coupled
to the mounting interface 1130 of the drive module 1100. More
specifically, the proximal portion 2100 of the shaft assembly 2000
comprises a housing 2110 which defines the mounting interface 2130.
Referring primarily to FIG. 8, the drive module 1100 comprises
latches 1140 which are configured to releasably hold the mounting
interface 2130 of the shaft assembly 2000 against the mounting
interface 1130 of the drive module 1100. When the drive module 1100
and the shaft assembly 2000 are brought together along a
longitudinal axis, as described above, the latches 1140 contact the
mounting interface 2130 and rotate outwardly into an unlocked
position. Referring primarily to FIGS. 8, 10, and 11, each latch
1140 comprises a lock end 1142 and a pivot portion 1144. The pivot
portion 1144 of each latch 1140 is rotatably coupled to the housing
1110 of the drive module 1100 and, when the latches 1140 are
rotated outwardly, as mentioned above, the latches 1140 rotate
about the pivot portions 1144. Notably, each latch 1140 further
comprises a biasing spring 1146 configured to bias the latches 1140
inwardly into a locked position. Each biasing spring 1146 is
compressed between a latch 1140 and the housing 1110 of the drive
module 1100 such that the biasing springs 1146 apply biasing forces
to the latches 1140; however, such biasing forces are overcome when
the latches 1140 are rotated outwardly into their unlocked
positions by the shaft assembly 2000. That said, when the latches
1140 rotate outwardly after contacting the mounting interface 2130,
the lock ends 1142 of the latches 1140 can enter into latch windows
2140 defined in the mounting interface 2130. Once the lock ends
1142 pass through the latch windows 2140, the springs 1146 can bias
the latches 1140 back into their locked positions. Each lock end
1142 comprises a lock shoulder, or surface, which securely holds
the shaft assembly 2000 to the drive module 1100.
[0242] Further to the above, the biasing springs 1146 hold the
latches 1140 in their locked positions. The distal ends 1142 are
sized and configured to prevent, or at least inhibit, relative
longitudinal movement, i.e., translation along a longitudinal axis,
between the shaft assembly 2000 and the drive module 1100 when the
latches 1140 are in their locked positions. Moreover, the latches
1140 and the latch windows 1240 are sized and configured to prevent
relative lateral movement, i.e., translation transverse to the
longitudinal axis, between the shaft assembly 2000 and the drive
module 1100. In addition, the latches 1140 and the latch windows
2140 are sized and configured to prevent the shaft assembly 2000
from rotating relative to the drive module 1100. The drive module
1100 further comprises release actuators 1150 which, when depressed
by a clinician, move the latches 1140 from their locked positions
into their unlocked positions. The drive module 1100 comprises a
first release actuator 1150 slideably mounted in an opening defined
in the first side of the handle housing 1110 and a second release
actuator 1150 slideably mounted in an opening defined in a second,
or opposite, side of the handle housing 1110. Although the release
actuators 1150 are actuatable separately, both release actuators
1150 typically need to be depressed to completely unlock the shaft
assembly 2000 from the drive module 1100 and allow the shaft
assembly 2000 to be detached from the drive module 1100. That said,
it is possible that the shaft assembly 2000 could be detached from
the drive module 1100 by depressing only one release actuator
1150.
[0243] Once the shaft assembly 2000 has been secured to the handle
1000 and the end effector 7000, for example, has been assembled to
the shaft 2000, the clinician can maneuver the handle 1000 to
insert the end effector 7000 into a patient. In at least one
instance, the end effector 7000 is inserted into the patient
through a trocar and then manipulated in order to position the jaw
assembly 7100 of the end effector assembly 7000 relative to the
patient's tissue. Oftentimes, the jaw assembly 7100 must be in its
closed, or clamped, configuration in order to fit through the
trocar. Once through the trocar, the jaw assembly 7100 can be
opened so that the patient tissue fit between the jaws of the jaw
assembly 7100. At such point, the jaw assembly 7100 can be returned
to its closed configuration to clamp the patient tissue between the
jaws. The clamping force applied to the patient tissue by the jaw
assembly 7100 is sufficient to move or otherwise manipulate the
tissue during a surgical procedure. Thereafter, the jaw assembly
7100 can be re-opened to release the patient tissue from the end
effector 7000. This process can be repeated until it is desirable
to remove the end effector 7000 from the patient. At such point,
the jaw assembly 7100 can be returned to its closed configuration
and retracted through the trocar. Other surgical techniques are
envisioned in which the end effector 7000 is inserted into a
patient through an open incision, or without the use of the trocar.
In any event, it is envisioned that the jaw assembly 7100 may have
to be opened and closed several times throughout a surgical
technique.
[0244] Referring again to FIGS. 3-6, the shaft assembly 2000
further comprises a clamping trigger system 2600 and a control
system 2800. The clamping trigger system 2600 comprises a clamping
trigger 2610 rotatably connected to the proximal housing 2110 of
the shaft assembly 2000. As discussed below, the clamping trigger
2610 actuates the motor 1610 to operate the jaw drive of the end
effector 7000 when the clamping trigger 2610 is actuated. The
clamping trigger 2610 comprises an elongate portion which is
graspable by the clinician while holding the handle 1000. The
clamping trigger 2610 further comprises a mounting portion 2620
which is pivotably connected to a mounting portion 2120 of the
proximal housing 2110 such that the clamping trigger 2610 is
rotatable about a fixed, or an at least substantially fixed, axis.
The closure trigger 2610 is rotatable between a distal position and
a proximal position, wherein the proximal position of the closure
trigger 2610 is closer to the pistol grip of the handle 1000 than
the distal position. The closure trigger 2610 further comprises a
tab 2615 extending therefrom which rotates within the proximal
housing 2110. When the closure trigger 2610 is in its distal
position, the tab 2615 is positioned above, but not in contact
with, a switch 2115 mounted on the proximal housing 2110. The
switch 2115 is part of an electrical circuit configured to detect
the actuation of the closure trigger 2610 which is in an open
condition the closure trigger 2610 is in its open position. When
the closure trigger 2610 is moved into its proximal position, the
tab 2615 comes into contact with the switch 2115 and closes the
electrical circuit. In various instances, the switch 2115 can
comprise a toggle switch, for example, which is mechanically
switched between open and closed states when contacted by the tab
2615 of the closure trigger 2610. In certain instances, the switch
2115 can comprise a proximity sensor, for example, and/or any
suitable type of sensor. In at least one instance, the switch 2115
comprises a Hall Effect sensor which can detect the amount in which
the closure trigger 2610 has been rotated and, based on the amount
of rotation, control the speed in which the motor 1610 is operated.
In such instances, larger rotations of the closure trigger 2610
result in faster speeds of the motor 1610 while smaller rotations
result in slower speeds, for example. In any event, the electrical
circuit is in communication with the control system 2800 of the
shaft assembly 2000, which is discussed in greater detail
below.
[0245] Further to the above, the control system 2800 of the shaft
assembly 2000 comprises a printed circuit board (PCB) 2810, at
least one microprocessor 2820, and at least one memory device 2830.
The board 2810 can be rigid and/or flexible and can comprise any
suitable number of layers. The microprocessor 2820 and the memory
device 2830 are part of a control circuit defined on the board 2810
which communicates with the control system 1800 of the handle 1000.
The shaft assembly 2000 further comprises a signal communication
system 2900 and the handle 1000 further comprises a signal
communication system 1900 which are configured to convey data
between the shaft control system 2800 and the handle control system
1800. The signal communication system 2900 is configured to
transmit data to the signal communication system 1900 utilizing any
suitable analog and/or digital components. In various instances,
the communication systems 2900 and 1900 can communicate using a
plurality of discrete channels which allows the input gates of the
microprocessor 1820 to be directly controlled, at least in part, by
the output gates of the microprocessor 2820. In some instances, the
communication systems 2900 and 1900 can utilize multiplexing. In at
least one such instance, the control system 2900 includes a
multiplexing device that sends multiple signals on a carrier
channel at the same time in the form of a single, complex signal to
a multiplexing device of the control system 1900 that recovers the
separate signals from the complex signal.
[0246] The communication system 2900 comprises an electrical
connector 2910 mounted to the circuit board 2810. The electrical
connector 2910 comprises a connector body and a plurality of
electrically-conductive contacts mounted to the connector body. The
electrically-conductive contacts comprise male pins, for example,
which are soldered to electrical traces defined in the circuit
board 2810. In other instances, the male pins can be in
communication with circuit board traces through
zero-insertion-force (ZIF) sockets, for example. The communication
system 1900 comprises an electrical connector 1910 mounted to the
circuit board 1810. The electrical connector 1910 comprises a
connector body and a plurality of electrically-conductive contacts
mounted to the connector body. The electrically-conductive contacts
comprise female pins, for example, which are soldered to electrical
traces defined in the circuit board 1810. In other instances, the
female pins can be in communication with circuit board traces
through zero-insertion-force (ZIF) sockets, for example. When the
shaft assembly 2000 is assembled to the drive module 1100, the
electrical connector 2910 is operably coupled to the electrical
connector 1910 such that the electrical contacts form electrical
pathways therebetween. The above being said, the connectors 1910
and 2910 can comprise any suitable electrical contacts. Moreover,
the communication systems 1900 and 2900 can communicate with one
another in any suitable manner. In various instances, the
communication systems 1900 and 2900 communicate wirelessly. In at
least one such instance, the communication system 2900 comprises a
wireless signal transmitter and the communication system 1900
comprises a wireless signal receiver such that the shaft assembly
2000 can wirelessly communicate data to the handle 1000. Likewise,
the communication system 1900 can comprise a wireless signal
transmitter and the communication system 2900 can comprise a
wireless signal receiver such that the handle 1000 can wirelessly
communicate data to the shaft assembly 2000.
[0247] As discussed above, the control system 1800 of the handle
1000 is in communication with, and is configured to control, the
electrical power circuit of the handle 1000. The handle control
system 1800 is also powered by the electrical power circuit of the
handle 1000. The handle communication system 1900 is in signal
communication with the handle control system 1800 and is also
powered by the electrical power circuit of the handle 1000. The
handle communication system 1900 is powered by the handle
electrical power circuit via the handle control system 1800, but
could be directly powered by the electrical power circuit. As also
discussed above, the handle communication system 1900 is in signal
communication with the shaft communication system 2900. That said,
the shaft communication system 2900 is also powered by the handle
electrical power circuit via the handle communication system 1900.
To this end, the electrical connectors 1910 and 2010 connect both
one or more signal circuits and one or more power circuits between
the handle 1000 and the shaft assembly 2000. Moreover, the shaft
communication system 2900 is in signal communication with the shaft
control system 2800, as discussed above, and is also configured to
supply power to the shaft control system 2800. Thus, the control
systems 1800 and 2800 and the communication systems 1900 and 2900
are all powered by the electrical power circuit of the handle 1000;
however, alternative embodiments are envisioned in which the shaft
assembly 2000 comprises its own power source, such as one or more
batteries, for example, an and electrical power circuit configured
to supply power from the batteries to the handle systems 2800 and
2900. In at least one such embodiment, the handle control system
1800 and the handle communication system 1900 are powered by the
handle electrical power system and the shaft control system 2800
and the handle communication system 2900 are powered by the shaft
electrical power system.
[0248] Further to the above, the actuation of the clamping trigger
2610 is detected by the shaft control system 2800 and communicated
to the handle control system 1800 via the communication systems
2900 and 1900. Upon receiving a signal that the clamping trigger
2610 has been actuated, the handle control system 1800 supplies
power to the electric motor 1610 of the motor assembly 1600 to
rotate the drive shaft 1710 of the handle drive system 1700, and
the drive shaft 2710 of the shaft drive system 2700, in a direction
which closes the jaw assembly 7100 of the end effector 7000. The
mechanism for converting the rotation of the drive shaft 2710 to a
closure motion of the jaw assembly 7100 is discussed in greater
detail below. So long as the clamping trigger 2610 is held in its
actuated position, the electric motor 1610 will rotate the drive
shaft 1710 until the jaw assembly 7100 reaches its fully-clamped
position. When the jaw assembly 7100 reaches its fully-clamped
position, the handle control system 1800 cuts the electrical power
to the electric motor 1610. The handle control system 1800 can
determine when the jaw assembly 7100 has reached its fully-clamped
position in any suitable manner. For instance, the handle control
system 1800 can comprise an encoder system which monitors the
rotation of, and counts the rotations of, the output shaft of the
electric motor 1610 and, once the number of rotations reaches a
predetermined threshold, the handle control system 1800 can
discontinue supplying power to the electric motor 1610. In at least
one instance, the end effector assembly 7000 can comprise one or
more sensors configured to detect when the jaw assembly 7100 has
reached its fully-clamped position. In at least one such instance,
the sensors in the end effector 7000 are in signal communication
with the handle control system 1800 via electrical circuits
extending through the shaft assembly 2000 which can include the
electrical contacts 1520 and 2520, for example.
[0249] When the clamping trigger 2610 is rotated distally out of
its proximal position, the switch 2115 is opened which is detected
by the shaft control system 2800 and communicated to the handle
control system 1800 via the communication systems 2900 and 1900.
Upon receiving a signal that the clamping trigger 2610 has been
moved out of its actuated position, the handle control system 1800
reverses the polarity of the voltage differential being applied to
the electric motor 1610 of the motor assembly 1600 to rotate the
drive shaft 1710 of the handle drive system 1700, and the drive
shaft 2710 of the shaft drive system 2700, in an opposite direction
which, as a result, opens the jaw assembly 7100 of the end effector
7000. When the jaw assembly 7100 reaches its fully-open position,
the handle control system 1800 cuts the electrical power to the
electric motor 1610. The handle control system 1800 can determine
when the jaw assembly 7100 has reached its fully-open position in
any suitable manner. For instance, the handle control system 1800
can utilize the encoder system and/or the one or more sensors
described above to determine the configuration of the jaw assembly
7100. In view of the above, the clinician needs to be mindful about
holding the clamping trigger 2610 in its actuated position in order
to maintain the jaw assembly 7100 in its clamped configuration as,
otherwise, the control system 1800 will open jaw assembly 7100.
With this in mind, the shaft assembly 2000 further comprises an
actuator latch 2630 configured to releasably hold the clamping
trigger 2610 in its actuated position to prevent the accidental
opening of the jaw assembly 7100. The actuator latch 2630 can be
manually released, or otherwise defeated, by the clinician to allow
the clamping trigger 2610 to be rotated distally and open the jaw
assembly 7100.
[0250] The clamping trigger system 2600 further comprises a
resilient biasing member, such as a torsion spring, for example,
configured to resist the closure of the clamping trigger system
2600. The torsion spring can also assist in reducing and/or
mitigating sudden movements and/or jitter of the clamping trigger
2610. Such a torsion spring can also automatically return the
clamping trigger 2610 to its unactuated position when the clamping
trigger 2610 is released. The actuator latch 2630 discussed above
can suitably hold the clamping trigger 2610 in its actuated
position against the biasing force of the torsion spring.
[0251] As discussed above, the control system 1800 operates the
electric motor 1610 to open and close the jaw assembly 7100. The
control system 1800 is configured to open and close the jaw
assembly 7100 at the same speed. In such instances, the control
system 1800 applies the same voltage pulses to the electric motor
1610, albeit with different voltage polarities, when opening and
closing the jaw assembly 7100. That said, the control system 1800
can be configured to open and close the jaw assembly 7100 at
different speeds. For instance, the jaw assembly 7100 can be closed
at a first speed and opened at a second speed which is faster than
the first speed. In such instances, the slower closing speed
affords the clinician an opportunity to better position the jaw
assembly 7100 while clamping the tissue. Alternatively, the control
system 1800 can open the jaw assembly 7100 at a slower speed. In
such instances, the slower opening speed reduces the possibility of
the opening jaws colliding with adjacent tissue. In either event,
the control system 1800 can decrease the duration of the voltage
pulses and/or increase the duration between the voltage pulses to
slow down and/or speed up the movement of the jaw assembly
7100.
[0252] As discussed above, the control system 1800 is configured to
interpret the position of the clamping trigger 2610 as a command to
position the jaw assembly 7100 in a specific configuration. For
instance, the control system 1800 is configured to interpret the
proximal-most position of the clamping trigger 2610 as a command to
close the jaw assembly 7100 and any other position of the clamping
trigger as a command to open the jaw assembly 7100. That said, the
control system 1800 can be configured to interpret the position of
the clamping trigger 2610 in a proximal range of positions, instead
of a single position, as a command to close the jaw assembly 7100.
Such an arrangement can allow the jaw assembly 7000 to be better
responsive to the clinician's input. In such instances, the range
of motion of the clamping trigger 2610 is divided into ranges--a
proximal range which is interpreted as a command to close the jaw
assembly 7100 and a distal range which is interpreted as a command
to open the jaw assembly 7100. In at least one instance, the range
of motion of the clamping trigger 2610 can have an intermediate
range between the proximal range and the distal range. When the
clamping trigger 2610 is in the intermediate range, the control
system 1800 can interpret the position of the clamping trigger 2610
as a command to neither open nor close the jaw assembly 7100. Such
an intermediate range can prevent, or reduce the possibility of,
jitter between the opening and closing ranges. In the instances
described above, the control system 1800 can be configured to
ignore cumulative commands to open or close the jaw assembly 7100.
For instance, if the closure trigger 2610 has already been fully
retracted into its proximal-most position, the control assembly
1800 can ignore the motion of the clamping trigger 2610 in the
proximal, or clamping, range until the clamping trigger 2610 enters
into the distal, or opening, range wherein, at such point, the
control system 1800 can then actuate the electric motor 1610 to
open the jaw assembly 7100.
[0253] In certain instances, further to the above, the position of
the clamping trigger 2610 within the clamping trigger range, or at
least a portion of the clamping trigger range, can allow the
clinician to control the speed of the electric motor 1610 and,
thus, the speed in which the jaw assembly 7100 is being opened or
closed by the control assembly 1800. In at least one instance, the
sensor 2115 comprises a Hall Effect sensor, and/or any other
suitable sensor, configured to detect the position of the clamping
trigger 2610 between its distal, unactuated position and its
proximal, fully-actuated position. The Hall Effect sensor is
configured to transmit a signal to the handle control system 1800
via the shaft control system 2800 such that the handle control
system 1800 can control the speed of the electric motor 1610 in
response to the position of the clamping trigger 2610. In at least
one instance, the handle control system 1800 controls the speed of
the electric motor 1610 proportionately, or in a linear manner, to
the position of the clamping trigger 2610. For example, if the
clamping trigger 2610 is moved half way through its range, then the
handle control system 1800 will operate the electric motor 1610 at
half of the speed in which the electric motor 1610 is operated when
the clamping trigger 2610 is fully-retracted. Similarly, if the
clamping trigger 2610 is moved a quarter way through its range,
then the handle control system 1800 will operate the electric motor
1610 at a quarter of the speed in which the electric motor 1610 is
operated when the clamping trigger 2610 is fully-retracted. Other
embodiments are envisioned in which the handle control system 1800
controls the speed of the electric motor 1610 in a non-linear
manner to the position of the clamping trigger 2610. In at least
one instance, the control system 1800 operates the electric motor
1610 slowly in the distal portion of the clamping trigger range
while quickly accelerating the speed of the electric motor 1610 in
the proximal portion of the clamping trigger range.
[0254] As described above, the clamping trigger 2610 is movable to
operate the electric motor 1610 to open or close the jaw assembly
7100 of the end effector 7000. The electric motor 1610 is also
operable to rotate the end effector 7000 about a longitudinal axis
and articulate the end effector 7000 relative to the elongate shaft
2200 about the articulation joint 2300 of the shaft assembly 2000.
Referring primarily to FIGS. 7 and 8, the drive module 1100
comprises an input system 1400 including a rotation actuator 1420
and an articulation actuator 1430. The input system 1400 further
comprises a printed circuit board (PCB) 1410 which is in signal
communication with the printed circuit board (PCB) 1810 of the
control system 1800. The drive module 1100 comprises an electrical
circuit, such as a flexible wiring harness or ribbon, for example,
which permits the input system 1400 to communicate with the control
system 1800. The rotation actuator 1420 is rotatably supported on
the housing 1110 and is in signal communication with the input
board 1410 and/or control board 1810, as described in greater
detail below. The articulation actuator 1430 is supported by and in
signal communication with the input board 1410 and/or control board
1810, as also described in greater detail below.
[0255] Referring primarily to FIGS. 8, 10, and 11, further to the
above, the handle housing 1110 comprises an annular groove or slot
defined therein adjacent the distal mounting interface 1130. The
rotation actuator 1420 comprises an annular ring 1422 rotatably
supported within the annular groove and, owing to the configuration
of the sidewalls of the annular groove, the annular ring 1422 is
constrained from translating longitudinally and/or laterally with
respect to the handle housing 1110. The annular ring 1422 is
rotatable in a first, or clockwise, direction and a second, or
counter-clockwise direction, about a longitudinal axis extending
through the frame 1500 of the drive module 1100. The rotation
actuator 1420 comprises one or more sensors configured to detect
the rotation of the annular ring 1422. In at least one instance,
the rotation actuator 1420 comprises a first sensor positioned on a
first side of the drive module 1100 and a second sensor positioned
on a second, or opposite, side of the drive module 1100 and the
annular ring 1422 comprises a detectable element which is
detectable by the first and second sensors. The first sensor is
configured to detect when the annular ring 1422 is rotated in the
first direction and the second sensor is configured to detect when
the annular ring 1422 is rotated in the second direction. When the
first sensor detects that the annular ring 1422 is rotated in the
first direction, the handle control system 1800 rotates the handle
drive shaft 1710, the drive shaft 2710, and the end effector 7000
in the first direction, as described in greater detail below.
Similarly, the handle control system 1800 rotates the handle drive
shaft 1710, the drive shaft 2710, and the end effector 7000 in the
second direction when the second sensor detects that the annular
ring 1422 is rotated in the second direction. In view of the above,
the reader should appreciate that the clamping trigger 2610 and the
rotation actuator 1420 are both operable to rotate the drive shaft
2710.
[0256] In various embodiments, further to the above, the first and
second sensors comprise switches which are mechanically closable by
the detectable element of the annular ring 1422. When the annular
ring 1422 is rotated in the first direction from a center position,
the detectable element closes the switch of the first sensor. When
the switch of the first sensor is closed, the control system 1800
operates the electric motor 1610 to rotate the end effector 7000 in
the first direction. When the annular ring 1422 is rotated in the
second direction toward the center position, the detectable element
is disengaged from the first switch and the first switch is
re-opened. Once the first switch is re-opened, the control system
1800 cuts the power to the electric motor 1610 to stop the rotation
of the end effector 7000. Similarly, the detectable element closes
the switch of the second sensor when the annular ring 1422 is
rotated in the second direction from the center position. When the
switch of the second sensor is closed, the control system 1800
operates the electric motor 1610 to rotate the end effector 7000 in
the second direction. When the annular ring 1422 is rotated in the
first direction toward the center position, the detectable element
is disengaged from the second switch and the second switch is
re-opened. Once the second switch is re-opened, the control system
1800 cuts the power to the electric motor 1610 to stop the rotation
of the end effector 7000.
[0257] In various embodiments, further to the above, the first and
second sensors of the rotation actuator 1420 comprise proximity
sensors, for example. In certain embodiments, the first and second
sensors of the rotation actuator 1420 comprise Hall Effect sensors,
and/or any suitable sensors, configured to detect the distance
between the detectable element of the annular ring 1422 and the
first and second sensors. If the first Hall Effect sensor detects
that the annular ring 1422 has been rotated in the first direction,
then, as discussed above, the control system 1800 will rotate the
end effector 7000 in the first direction. In addition, the control
system 1800 can rotate the end effector 7000 at a faster speed when
the detectable element is closer to the first Hall Effect sensor
than when the detectable element is further away from the first
Hall Effect sensor. If the second Hall Effect sensor detects that
the annular ring 1422 has been rotated in the second direction,
then, as discussed above, the control system 1800 will rotate the
end effector 7000 in the second direction. In addition, the control
system 1800 can rotate the end effector 7000 at a faster speed when
the detectable element is closer to the second Hall Effect sensor
than when the detectable element is further away from the second
Hall Effect sensor. As a result, the speed in which the end
effector 7000 is rotated is a function of the amount, or degree, in
which the annular ring 1422 is rotated. The control system 1800 is
further configured to evaluate the inputs from both the first and
second Hall Effect sensors when determining the direction and speed
in which to rotate the end effector 7000. In various instances, the
control system 1800 can use the closest Hall Effect sensor to the
detectable element of the annular ring 1422 as a primary source of
data and the Hall Effect sensor furthest away from the detectable
element as a conformational source of data to double-check the data
provided by the primary source of data. The control system 1800 can
further comprise a data integrity protocol to resolve situations in
which the control system 1800 is provided with conflicting data. In
any event, the handle control system 1800 can enter into a neutral
state in which the handle control system 1800 does not rotate the
end effector 7000 when the Hall Effect sensors detect that the
detectable element is in its center position, or in a position
which is equidistant between the first Hall Effect sensor and the
second Hall Effect sensor. In at least one such instance, the
control system 1800 can enter into its neutral state when the
detectable element is in a central range of positions. Such an
arrangement would prevent, or at least reduce the possibility of,
rotational jitter when the clinician is not intending to rotate the
end effector 7000.
[0258] Further to the above, the rotation actuator 1420 can
comprise one or more springs configured to center, or at least
substantially center, the rotation actuator 1420 when it is
released by the clinician. In such instances, the springs can act
to shut off the electric motor 1610 and stop the rotation of the
end effector 7000. In at least one instance, the rotation actuator
1420 comprises a first torsion spring configured to rotate the
rotation actuator 1420 in the first direction and a second torsion
spring configured to rotate the rotation actuator 1420 in the
second direction. The first and second torsion springs can have the
same, or at least substantially the same, spring constant such that
the forces and/or torques applied by the first and second torsion
springs balance, or at least substantially balance, the rotation
actuator 1420 in its center position.
[0259] In view of the above, the reader should appreciate that the
clamping trigger 2610 and the rotation actuator 1420 are both
operable to rotate the drive shaft 2710 and either, respectively,
operate the jaw assembly 7100 or rotate the end effector 7000. The
system that uses the rotation of the drive shaft 2710 to
selectively perform these functions is described in greater detail
below.
[0260] Referring to FIGS. 7 and 8, the articulation actuator 1430
comprises a first push button 1432 and a second push button 1434.
The first push button 1432 is part of a first articulation control
circuit and the second push button 1434 is part of a second
articulation circuit of the input system 1400. The first push
button 1432 comprises a first switch that is closed when the first
push button 1432 is depressed. The handle control system 1800 is
configured to sense the closure of the first switch and, moreover,
the closure of the first articulation control circuit. When the
handle control system 1800 detects that the first articulation
control circuit has been closed, the handle control system 1800
operates the electric motor 1610 to articulate the end effector
7000 in a first articulation direction about the articulation joint
2300. When the first push button 1432 is released by the clinician,
the first articulation control circuit is opened which, once
detected by the control system 1800, causes the control system 1800
to cut the power to the electric motor 1610 to stop the
articulation of the end effector 7000.
[0261] In various instances, further to the above, the articulation
range of the end effector 7000 is limited and the control system
1800 can utilize the encoder system discussed above for monitoring
the rotational output of the electric motor 1610, for example, to
monitor the amount, or degree, in which the end effector 7000 is
rotated in the first direction. In addition to or in lieu of the
encoder system, the shaft assembly 2000 can comprise a first sensor
configured to detect when the end effector 7000 has reached the
limit of its articulation in the first direction. In any event,
when the control system 1800 determines that the end effector 7000
has reached the limit of articulation in the first direction, the
control system 1800 can cut the power to the electric motor 1610 to
stop the articulation of the end effector 7000.
[0262] Similar to the above, the second push button 1434 comprises
a second switch that is closed when the second push button 1434 is
depressed. The handle control system 1800 is configured to sense
the closure of the second switch and, moreover, the closure of the
second articulation control circuit. When the handle control system
1800 detects that the second articulation control circuit has been
closed, the handle control system 1800 operates the electric motor
1610 to articulate the end effector 7000 in a second direction
about the articulation joint 2300. When the second push button 1434
is released by the clinician, the second articulation control
circuit is opened which, once detected by the control system 1800,
causes the control system 1800 to cut the power to the electric
motor 1610 to stop the articulation of the end effector 7000.
[0263] In various instances, the articulation range of the end
effector 7000 is limited and the control system 1800 can utilize
the encoder system discussed above for monitoring the rotational
output of the electric motor 1610, for example, to monitor the
amount, or degree, in which the end effector 7000 is rotated in the
second direction. In addition to or in lieu of the encoder system,
the shaft assembly 2000 can comprise a second sensor configured to
detect when the end effector 7000 has reached the limit of its
articulation in the second direction. In any event, when the
control system 1800 determines that the end effector 7000 has
reached the limit of articulation in the second direction, the
control system 1800 can cut the power to the electric motor 1610 to
stop the articulation of the end effector 7000.
[0264] As described above, the end effector 7000 is articulatable
in a first direction (FIG. 16) and/or a second direction (FIG. 17)
from a center, or unarticulated, position (FIG. 15). Once the end
effector 7000 has been articulated, the clinician can attempt to
re-center the end effector 7000 by using the first and second
articulation push buttons 1432 and 1434. As the reader can
appreciate, the clinician may struggle to re-center the end
effector 7000 as, for instance, the end effector 7000 may not be
entirely visible once it is positioned in the patient. In some
instances, the end effector 7000 may not fit back through a trocar
if the end effector 7000 is not re-centered, or at least
substantially re-centered. With that in mind, the control system
1800 is configured to provide feedback to the clinician when the
end effector 7000 is moved into its unarticulated, or centered,
position. In at least one instance, the feedback comprises audio
feedback and the handle control system 1800 can comprise a speaker
which emits a sound, such as a beep, for example, when the end
effector 7000 is centered. In certain instances, the feedback
comprises visual feedback and the handle control system 1800 can
comprise a light emitting diode (LED), for example, positioned on
the handle housing 1110 which flashes when the end effector 7000 is
centered. In various instances, the feedback comprises haptic
feedback and the handle control system 1800 can comprise an
electric motor comprising an eccentric element which vibrates the
handle 1000 when the end effector 7000 is centered. Manually
re-centering the end effector 7000 in this way can be facilitated
by the control system 1800 slowing the motor 1610 when the end
effector 7000 is approaching its centered position. In at least one
instance, the control system 1800 slows the articulation of the end
effector 7000 when the end effector 7000 is within approximately 5
degrees of center in either direction, for example.
[0265] In addition to or in lieu of the above, the handle control
system 1800 can be configured to re-center the end effector 7000.
In at least one such instance, the handle control system 1800 can
re-center the end effector 7000 when both of the articulation
buttons 1432 and 1434 of the articulation actuator 1430 are
depressed at the same time. When the handle control system 1800
comprises an encoder system configured to monitor the rotational
output of the electric motor 1610, for example, the handle control
system 1800 can determine the amount and direction of articulation
needed to re-center, or at least substantially re-center, the end
effector 7000. In various instances, the input system 1400 can
comprise a home button, for example, which, when depressed,
automatically centers the end effector 7000.
[0266] Referring primarily to FIGS. 5 and 6, the elongate shaft
2200 of the shaft assembly 2000 comprises an outer housing, or
tube, 2210 mounted to the proximal housing 2110 of the proximal
portion 2100. The outer housing 2210 comprises a longitudinal
aperture 2230 extending therethrough and a proximal flange 2220
which secures the outer housing 2210 to the proximal housing 2110.
The frame 2500 of the shaft assembly 2000 extends through the
longitudinal aperture 2230 of the elongate shaft 2200. More
specifically, the shaft 2510 of the shaft frame 2500 necks down
into a smaller shaft 2530 which extends through the longitudinal
aperture 2230. That said, the shaft frame 2500 can comprise any
suitable arrangement. The drive system 2700 of the shaft assembly
2000 also extends through the longitudinal aperture 2230 of the
elongate shaft 2200. More specifically, the drive shaft 2710 of the
shaft drive system 2700 necks down into a smaller drive shaft 2730
which extends through the longitudinal aperture 2230. That said,
the shaft drive system 2700 can comprise any suitable
arrangement.
[0267] Referring primarily to FIGS. 20, 23, and 24, the outer
housing 2210 of the elongate shaft 2200 extends to the articulation
joint 2300. The articulation joint 2300 comprises a proximal frame
2310 mounted to the outer housing 2210 such that there is little,
if any, relative translation and/or rotation between the proximal
frame 2310 and the outer housing 2210. Referring primarily to FIG.
22, the proximal frame 2310 comprises an annular portion 2312
mounted to the sidewall of the outer housing 2210 and tabs 2314
extending distally from the annular portion 2312. The articulation
joint 2300 further comprises links 2320 and 2340 which are
rotatably mounted to the frame 2310 and mounted to an outer housing
2410 of the distal attachment portion 2400. The link 2320 comprises
a distal end 2322 mounted to the outer housing 2410. More
specifically, the distal end 2322 of the link 2320 is received and
fixedly secured within a mounting slot 2412 defined in the outer
housing 2410. Similarly, the link 2340 comprises a distal end 2342
mounted to the outer housing 2410. More specifically, the distal
end 2342 of the link 2340 is received and fixedly secured within a
mounting slot defined in the outer housing 2410. The link 2320
comprises a proximal end 2324 rotatably coupled to a tab 2314 of
the proximal articulation frame 2310. Although not illustrated in
FIG. 22, a pin extends through apertures defined in the proximal
end 2324 and the tab 2314 to define a pivot axis therebetween.
Similarly, the link 2340 comprises a proximal end 2344 rotatably
coupled to a tab 2314 of the proximal articulation frame 2310.
Although not illustrated in FIG. 22, a pin extends through
apertures defined in the proximal end 2344 and the tab 2314 to
define a pivot axis therebetween. These pivot axes are collinear,
or at least substantially collinear, and define an articulation
axis A of the articulation joint 2300.
[0268] Referring primarily to FIGS. 20, 23, and 24, the outer
housing 2410 of the distal attachment portion 2400 comprises a
longitudinal aperture 2430 extending therethrough. The longitudinal
aperture 2430 is configured to receive a proximal attachment
portion 7400 of the end effector 7000. The end effector 7000
comprises an outer housing 6230 which is closely received within
the longitudinal aperture 2430 of the distal attachment portion
2400 such that there is little, if any, relative radial movement
between the proximal attachment portion 7400 of the end effector
7000 and the distal attachment portion 2400 of the shaft assembly
2000. The proximal attachment portion 7400 further comprises an
annular array of lock notches 7410 defined on the outer housing
6230 which is releasably engaged by an end effector lock 6400 in
the distal attachment portion 2400 of the shaft assembly 2000. When
the end effector lock 6400 is engaged with the array of lock
notches 7410, the end effector lock 6400 prevents, or at least
inhibits, relative longitudinal movement between the proximal
attachment portion 7400 of the end effector 7000 and the distal
attachment portion 2400 of the shaft assembly 2000. As a result of
the above, only relative rotation between the proximal attachment
portion 7400 of the end effector 7000 and the distal attachment
portion 2400 of the shaft assembly 2000 is permitted. To this end,
the outer housing 6230 of the end effector 7000 is closely received
within the longitudinal aperture 2430 defined in the distal
attachment portion 2400 of the shaft assembly 2000.
[0269] Further to the above, referring to FIG. 21, the outer
housing 6230 further comprises an annular slot, or recess, 6270
defined therein which is configured to receive an O-ring 6275
therein. The O-ring 6275 is compressed between the outer housing
6230 and the sidewall of the longitudinal aperture 2430 when the
end effector 7000 is inserted into the distal attachment portion
2400. The O-ring 6275 is configured to resist, but permit, relative
rotation between the end effector 7000 and the distal attachment
portion 2400 such that the O-ring 6275 can prevent, or reduce the
possibility of, unintentional relative rotation between the end
effector 7000 and the distal attachment portion 2400. In various
instances, the O-ring 6275 can provide a seal between the end
effector 7000 and the distal attachment portion 2400 to prevent, or
at least reduce the possibility of, fluid ingress into the shaft
assembly 2000, for example.
[0270] Referring to FIGS. 14-21, the jaw assembly 7100 of the end
effector 7000 comprises a first jaw 7110 and a second jaw 7120.
Each jaw 7110, 7120 comprises a distal end which is configured to
assist a clinician in dissecting tissue with the end effector 7000.
Each jaw 7110, 7120 further comprises a plurality of teeth which
are configured to assist a clinician in grasping and holding onto
tissue with the end effector 7000. Moreover, referring primarily to
FIG. 21, each jaw 7110, 7120 comprises a proximal end, i.e.,
proximal ends 7115, 7125, respectively, which rotatably connect the
jaws 7110, 7120 together. Each proximal end 7115, 7125 comprises an
aperture extending therethrough which is configured to closely
receive a pin 7130 therein. The pin 7130 comprises a central body
7135 closely received within the apertures defined in the proximal
ends 7115, 7125 of the jaws 7110, 7120 such that there is little,
if any, relative translation between the jaws 7110, 7120 and the
pin 7130. The pin 7130 defines a jaw axis J about which the jaws
7110, 7120 can be rotated and, also, rotatably mounts the jaws
7110, 7120 to the outer housing 6230 of the end effector 7000. More
specifically, the outer housing 6230 comprises distally-extending
tabs 6235 having apertures defined therein which are also
configured to closely receive the pin 7130 such that the jaw
assembly 7100 does not translate relative to a shaft portion 7200
of the end effector 7000. The pin 7130 further comprises enlarged
ends which prevent the jaws 7110, 7120 from becoming detached from
the pin 7130 and also prevents the jaw assembly 7100 from becoming
detached from the shaft portion 7200. This arrangement defines a
rotation joint 7300.
[0271] Referring primarily to FIGS. 21 and 23, the jaws 7110 and
7120 are rotatable between their open and closed positions by a jaw
assembly drive including drive links 7140, a drive nut 7150, and a
drive screw 6130. As described in greater detail below, the drive
screw 6130 is selectively rotatable by the drive shaft 2730 of the
shaft drive system 2700. The drive screw 6130 comprises an annular
flange 6132 which is closely received within a slot, or groove,
6232 (FIG. 25) defined in the outer housing 6230 of the end
effector 7000. The sidewalls of the slot 6232 are configured to
prevent, or at least inhibit, longitudinal and/or radial
translation between the drive screw 6130 and the outer housing
6230, but yet permit relative rotational motion between the drive
screw 6130 and the outer housing 6230. The drive screw 6130 further
comprises a threaded end 6160 which is threadably engaged with a
threaded aperture 7160 defined in the drive nut 7150. The drive nut
7150 is constrained from rotating with the drive screw 6130 and, as
a result, the drive nut 7150 is translated when the drive screw
6130 is rotated. In use, the drive screw 6130 is rotated in a first
direction to displace the drive nut 7150 proximally and in a
second, or opposite, direction to displace the drive nut 7150
distally. The drive nut 7150 further comprises a distal end 7155
comprising an aperture defined therein which is configured to
closely receive pins 7145 extending from the drive links 7140.
Referring primarily to FIG. 21, a first drive link 7140 is attached
to one side of the distal end 7155 and a second drive link 7140 is
attached to the opposite side of the distal end 7155. The first
drive link 7140 comprises another pin 7145 extending therefrom
which is closely received in an aperture defined in the proximal
end 7115 of the first jaw 7110 and, similarly, the second drive
link 7140 comprises another pin extending therefrom which is
closely received in an aperture defined in the proximal end 7125 of
the second jaw 7120. As a result of the above, the drive links 7140
operably connect the jaws 7110 and 7120 to the drive nut 7150. When
the drive nut 7150 is driven proximally by the drive screw 6130, as
described above, the jaws 7110, 7120 are rotated into the closed,
or clamped, configuration. Correspondingly, the jaws 7110, 7120 are
rotated into their open configuration when the drive nut 7150 is
driven distally by the drive screw 6130.
[0272] As discussed above, the control system 1800 is configured to
actuate the electric motor 1610 to perform three different end
effector functions--clamping/opening the jaw assembly 7100 (FIGS.
14 and 15), rotating the end effector 7000 about a longitudinal
axis (FIGS. 18 and 19), and articulating the end effector 7000
about an articulation axis (FIGS. 16 and 17). Referring primarily
to FIGS. 26 and 27, the control system 1800 is configured to
operate a transmission 6000 to selectively perform these three end
effector functions. The transmission 6000 comprises a first clutch
system 6100 configured to selectively transmit the rotation of the
drive shaft 2730 to the drive screw 6130 of the end effector 7000
to open or close the jaw assembly 7100, depending on the direction
in which the drive shaft 2730 is rotated. The transmission 6000
further comprises a second clutch system 6200 configured to
selectively transmit the rotation of the drive shaft 2730 to the
outer housing 6230 of the end effector 7000 to rotate the end
effector 7000 about the longitudinal axis L. The transmission 6000
also comprises a third clutch system 6300 configured to selectively
transmit the rotation of the drive shaft 2730 to the articulation
joint 2300 to articulate the distal attachment portion 2400 and the
end effector 7000 about the articulation axis A. The clutch systems
6100, 6200, and 6300 are in electrical communication with the
control system 1800 via electrical circuits extending through the
shaft 2510, the connector pins 2520, the connector pins 1520, and
the shaft 1510, for example. In at least one instance, each of
these clutch control circuits comprises two connector pins 2520 and
two connector pins 1520, for example.
[0273] In various instances, further to the above, the shaft 2510
and/or the shaft 1510 comprise a flexible circuit including
electrical traces which form part of the clutch control circuits.
The flexible circuit can comprise a ribbon, or substrate, with
conductive pathways defined therein and/or thereon. The flexible
circuit can also comprise sensors and/or any solid state component,
such as signal smoothing capacitors, for example, mounted thereto.
In at least one instance, each of the conductive pathways can
comprise one or more signal smoothing capacitors which can, among
other things, even out fluctuations in signals transmitted through
the conductive pathways. In various instances, the flexible circuit
can be coated with at least one material, such as an elastomer, for
example, which can seal the flexible circuit against fluid
ingress.
[0274] Referring primarily to FIG. 28, the first clutch system 6100
comprises a first clutch 6110, an expandable first drive ring 6120,
and a first electromagnetic actuator 6140. The first clutch 6110
comprises an annular ring and is slideably disposed on the drive
shaft 2730. The first clutch 6110 is comprised of a magnetic
material and is movable between a disengaged, or unactuated,
position (FIG. 28) and an engaged, or actuated, position (FIG. 29)
by electromagnetic fields EF generated by the first electromagnetic
actuator 6140. In various instances, the first clutch 6110 is at
least partially comprised of iron and/or nickel, for example. In at
least one instance, the first clutch 6110 comprises a permanent
magnet. As illustrated in FIG. 22A, the drive shaft 2730 comprises
one or more longitudinal key slots 6115 defined therein which are
configured to constrain the longitudinal movement of the clutch
6110 relative to the drive shaft 2730. More specifically, the
clutch 6110 comprises one or more keys extending into the key slots
6115 such that the distal ends of the key slots 6115 stop the
distal movement of the clutch 6110 and the proximal ends of the key
slots 6115 stop the proximal movement of the clutch 6110.
[0275] When the first clutch 6110 is in its disengaged position
(FIG. 28), the first clutch 6110 rotates with the drive shaft 2130
but does not transmit rotational motion to the first drive ring
6120. As can be seen in FIG. 28, the first clutch 6110 is separated
from, or not in contact with, the first drive ring 6120. As a
result, the rotation of the drive shaft 2730 and the first clutch
6110 is not transmitted to the drive screw 6130 when the first
clutch assembly 6100 is in its disengaged state. When the first
clutch 6110 is in its engaged position (FIG. 29), the first clutch
6110 is engaged with the first drive ring 6120 such that the first
drive ring 6120 is expanded, or stretched, radially outwardly into
contact with the drive screw 6130. In at least one instance, the
first drive ring 6120 comprises an elastomeric band, for example.
As can be seen in FIG. 29, the first drive ring 6120 is compressed
against an annular inner sidewall 6135 of the drive screw 6130. As
a result, the rotation of the drive shaft 2730 and the first clutch
6110 is transmitted to the drive screw 6130 when the first clutch
assembly 6100 is in its engaged state. Depending on the direction
in which the drive shaft 2730 is rotated, the first clutch assembly
6100 can move the jaw assembly 7100 into its open and closed
configurations when the first clutch assembly 6100 is in its
engaged state.
[0276] As described above, the first electromagnetic actuator 6140
is configured to generate magnetic fields to move the first clutch
6110 between its disengaged (FIG. 28) and engaged (FIG. 29)
positions. For instance, referring to FIG. 28, the first
electromagnetic actuator 6140 is configured to emit a magnetic
field EF.sub.L which repulses, or drives, the first clutch 6110
away from the first drive ring 6120 when the first clutch assembly
6100 is in its disengaged state. The first electromagnetic actuator
6140 comprises one or more wound coils in a cavity defined in the
shaft frame 2530 which generate the magnetic field EF.sub.L when
current flows in a first direction through a first electrical
clutch circuit including the wound coils. The control system 1800
is configured to apply a first voltage polarity to the first
electrical clutch circuit to create the current flowing in the
first direction. The control system 1800 can continuously apply the
first voltage polarity to the first electric shaft circuit to
continuously hold the first clutch 6110 in its disengaged position.
While such an arrangement can prevent the first clutch 6110 from
unintentionally engaging the first drive ring 6120, such an
arrangement can also consume a lot of power. Alternatively, the
control system 1800 can apply the first voltage polarity to the
first electrical clutch circuit for a sufficient period of time to
position the first clutch 6110 in its disengaged position and then
discontinue applying the first voltage polarity to the first
electric clutch circuit, thereby resulting in a lower consumption
of power. That being said, the first clutch assembly 6100 further
comprises a first clutch lock 6150 mounted in the drive screw 6130
which is configured to releasably hold the first clutch 6110 in its
disengaged position. The first clutch lock 6150 is configured to
prevent, or at least reduce the possibility of, the first clutch
6110 from becoming unintentionally engaged with the first drive
ring 6120. When the first clutch 6110 is in its disengaged
position, as illustrated in FIG. 28, the first clutch lock 6150
interferes with the free movement of the first clutch 6110 and
holds the first clutch 6110 in position via a friction force and/or
an interference force therebetween. In at least one instance, the
first clutch lock 6150 comprises an elastomeric plug, seat, or
detent, comprised of rubber, for example. In certain instances, the
first clutch lock 6150 comprises a permanent magnet which holds the
first clutch 6110 in its disengaged position by an electromagnetic
force. In any event, the first electromagnetic actuator 6140 can
apply an electromagnetic pulling force to the first clutch 6110
that overcomes these forces, as described in greater detail
below.
[0277] Further to the above, referring to FIG. 29, the first
electromagnetic actuator 6140 is configured to emit a magnetic
field EF.sub.D which pulls, or drives, the first clutch 6110 toward
the first drive ring 6120 when the first clutch assembly 6100 is in
its engaged state. The coils of the first electromagnetic actuator
6140 generate the magnetic field EF.sub.D when current flows in a
second, or opposite, direction through the first electrical clutch
circuit. The control system 1800 is configured to apply an opposite
voltage polarity to the first electrical clutch circuit to create
the current flowing in the opposite direction. The control system
1800 can continuously apply the opposite voltage polarity to the
first electrical clutch circuit to continuously hold the first
clutch 6110 in its engaged position and maintain the operable
engagement between the first drive ring 6120 and the drive screw
6130. Alternatively, the first clutch 6110 can be configured to
become wedged within the first drive ring 6120 when the first
clutch 6110 is in its engaged position and, in such instances, the
control system 1800 may not need to continuously apply a voltage
polarity to the first electrical clutch circuit to hold the first
clutch assembly 6100 in its engaged state. In such instances, the
control system 1800 can discontinue applying the voltage polarity
once the first clutch 6110 has been sufficiently wedged in the
first drive ring 6120.
[0278] Notably, further to the above, the first clutch lock 6150 is
also configured to lockout the jaw assembly drive when the first
clutch 6110 is in its disengaged position. More specifically,
referring again to FIG. 28, the first clutch 6110 pushes the first
clutch lock 6150 in the drive screw 6130 into engagement with the
outer housing 6230 of the end effector 7000 when the first clutch
6110 is in its disengaged position such that the drive screw 6130
does not rotate, or at least substantially rotate, relative to the
outer housing 6230. The outer housing 6230 comprises a slot 6235
defined therein which is configured to receive the first clutch
lock 6150. When the first clutch 6110 is moved into its engaged
position, referring to FIG. 29, the first clutch 6110 is no longer
engaged with the first clutch lock 6150 and, as a result, the first
clutch lock 6150 is no longer biased into engagement with the outer
housing 6230 and the drive screw 6130 can rotate freely with
respect to the outer housing 6230. As a result of the above, the
first clutch 6110 can do at least two things--operate the jaw drive
when the first clutch 6110 is in its engaged position and lock out
the jaw drive when the first clutch 6110 is in its disengaged
position.
[0279] Moreover, further to the above, the threads of the threaded
portions 6160 and 7160 can be configured to prevent, or at least
resist, backdriving of the jaw drive. In at least one instance, the
thread pitch and/or angle of the threaded portions 6160 and 7160,
for example, can be selected to prevent the backdriving, or
unintentional opening, of the jaw assembly 7100. As a result of the
above, the possibility of the jaw assembly 7100 unintentionally
opening or closing is prevented, or at least reduced.
[0280] Referring primarily to FIG. 30, the second clutch system
6200 comprises a second clutch 6210, an expandable second drive
ring 6220, and a second electromagnetic actuator 6240. The second
clutch 6210 comprises an annular ring and is slideably disposed on
the drive shaft 2730. The second clutch 6210 is comprised of a
magnetic material and is movable between a disengaged, or
unactuated, position (FIG. 30) and an engaged, or actuated,
position (FIG. 31) by electromagnetic fields EF generated by the
second electromagnetic actuator 6240. In various instances, the
second clutch 6210 is at least partially comprised of iron and/or
nickel, for example. In at least one instance, the second clutch
6210 comprises a permanent magnet. As illustrated in FIG. 22A, the
drive shaft 2730 comprises one or more longitudinal key slots 6215
defined therein which are configured to constrain the longitudinal
movement of the second clutch 6210 relative to the drive shaft
2730. More specifically, the second clutch 6210 comprises one or
more keys extending into the key slots 6215 such that the distal
ends of the key slots 6215 stop the distal movement of the second
clutch 6210 and the proximal ends of the key slots 6215 stop the
proximal movement of the second clutch 6210.
[0281] When the second clutch 6210 is in its disengaged position,
referring to FIG. 30, the second clutch 6210 rotates with the drive
shaft 2730 but does not transmit rotational motion to the second
drive ring 6220. As can be seen in FIG. 30, the second clutch 6210
is separated from, or not in contact with, the second drive ring
6220. As a result, the rotation of the drive shaft 2730 and the
second clutch 6210 is not transmitted to the outer housing 6230 of
the end effector 7000 when the second clutch assembly 6200 is in
its disengaged state. When the second clutch 6210 is in its engaged
position (FIG. 31), the second clutch 6210 is engaged with the
second drive ring 6220 such that the second drive ring 6220 is
expanded, or stretched, radially outwardly into contact with the
outer housing 6230. In at least one instance, the second drive ring
6220 comprises an elastomeric band, for example. As can be seen in
FIG. 31, the second drive ring 6220 is compressed against an
annular inner sidewall 7415 of the outer housing 6230. As a result,
the rotation of the drive shaft 2730 and the second clutch 6210 is
transmitted to the outer housing 6230 when the second clutch
assembly 6200 is in its engaged state. Depending on the direction
in which the drive shaft 2730 is rotated, the second clutch
assembly 6200 can rotate the end effector 7000 in a first direction
or a second direction about the longitudinal axis L when the second
clutch assembly 6200 is in its engaged state.
[0282] As described above, the second electromagnetic actuator 6240
is configured to generate magnetic fields to move the second clutch
6210 between its disengaged (FIG. 30) and engaged (FIG. 31)
positions. For instance, the second electromagnetic actuator 6240
is configured to emit a magnetic field EF.sub.L which repulses, or
drives, the second clutch 6210 away from the second drive ring 6220
when the second clutch assembly 6200 is in its disengaged state.
The second electromagnetic actuator 6240 comprises one or more
wound coils in a cavity defined in the shaft frame 2530 which
generate the magnetic field EF.sub.L when current flows in a first
direction through a second electrical clutch circuit including the
wound coils. The control system 1800 is configured to apply a first
voltage polarity to the second electrical clutch circuit to create
the current flowing in the first direction. The control system 1800
can continuously apply the first voltage polarity to the second
electric clutch circuit to continuously hold the second clutch 6120
in its disengaged position. While such an arrangement can prevent
the second clutch 6210 from unintentionally engaging the second
drive ring 6220, such an arrangement can also consume a lot of
power. Alternatively, the control system 1800 can apply the first
voltage polarity to the second electrical clutch circuit for a
sufficient period of time to position the second clutch 6210 in its
disengaged position and then discontinue applying the first voltage
polarity to the second electric clutch circuit, thereby resulting
in a lower consumption of power. That being said, the second clutch
assembly 6200 further comprises a second clutch lock 6250 mounted
in the outer housing 6230 which is configured to releasably hold
the second clutch 6210 in its disengaged position. Similar to the
above, the second clutch lock 6250 can prevent, or at least reduce
the possibility of, the second clutch 6210 from becoming
unintentionally engaged with the second drive ring 6220. When the
second clutch 6210 is in its disengaged position, as illustrated in
FIG. 30, the second clutch lock 6250 interferes with the free
movement of the second clutch 6210 and holds the second clutch 6210
in position via a friction and/or interference force therebetween.
In at least one instance, the second clutch lock 6250 comprises an
elastomeric plug, seat, or detent, comprised of rubber, for
example. In certain instances, the second clutch lock 6250
comprises a permanent magnet which holds the second clutch 6210 in
its disengaged position by an electromagnetic force. That said, the
second electromagnetic actuator 6240 can apply an electromagnetic
pulling force to the second clutch 6210 that overcomes these
forces, as described in greater detail below.
[0283] Further to the above, referring to FIG. 31, the second
electromagnetic actuator 6240 is configured to emit a magnetic
field EF.sub.D which pulls, or drives, the second clutch 6210
toward the second drive ring 6220 when the second clutch assembly
6200 is in its engaged state. The coils of the second
electromagnetic actuator 6240 generate the magnetic field EF.sub.D
when current flows in a second, or opposite, direction through the
second electrical shaft circuit. The control system 1800 is
configured to apply an opposite voltage polarity to the second
electrical shaft circuit to create the current flowing in the
opposite direction. The control system 1800 can continuously apply
the opposite voltage polarity to the second electric shaft circuit
to continuously hold the second clutch 6210 in its engaged position
and maintain the operable engagement between the second drive ring
6220 and the outer housing 6230. Alternatively, the second clutch
6210 can be configured to become wedged within the second drive
ring 6220 when the second clutch 6210 is in its engaged position
and, in such instances, the control system 1800 may not need to
continuously apply a voltage polarity to the second shaft
electrical circuit to hold the second clutch assembly 6200 in its
engaged state. In such instances, the control system 1800 can
discontinue applying the voltage polarity once the second clutch
6210 has been sufficiently wedged in the second drive ring
6220.
[0284] Notably, further to the above, the second clutch lock 6250
is also configured to lockout the rotation of the end effector 7000
when the second clutch 6210 is in its disengaged position. More
specifically, referring again to FIG. 30, the second clutch 6210
pushes the second clutch lock 6250 in the outer shaft 6230 into
engagement with the articulation link 2340 when the second clutch
6210 is in its disengaged position such that the end effector 7000
does not rotate, or at least substantially rotate, relative to the
distal attachment portion 2400 of the shaft assembly 2000. As
illustrated in FIG. 27, the second clutch lock 6250 is positioned
or wedged within a slot, or channel, 2345 defined in the
articulation link 2340 when the second clutch 6210 is in its
disengaged position. As a result of the above, the possibility of
the end effector 7000 unintentionally rotating is prevented, or at
least reduced. Moreover, as a result of the above, the second
clutch 6210 can do at least two things--operate the end effector
rotation drive when the second clutch 6210 is in its engaged
position and lock out the end effector rotation drive when the
second clutch 6210 is in its disengaged position.
[0285] Referring primarily to FIGS. 22, 24, and 25, the shaft
assembly 2000 further comprises an articulation drive system
configured to articulate the distal attachment portion 2400 and the
end effector 7000 about the articulation joint 2300. The
articulation drive system comprises an articulation drive 6330
rotatably supported within the distal attachment portion 2400. That
said, the articulation drive 6330 is closely received within the
distal attachment portion 2400 such that the articulation drive
6330 does not translate, or at least substantially translate,
relative to the distal attachment portion 2400. The articulation
drive system of the shaft assembly 2000 further comprises a
stationary gear 2330 fixedly mounted to the articulation frame
2310. More specifically, the stationary gear 2330 is fixedly
mounted to a pin connecting a tab 2314 of the articulation frame
2310 and the articulation link 2340 such that the stationary gear
2330 does not rotate relative to the articulation frame 2310. The
stationary gear 2330 comprises a central body 2335 and an annular
array of stationary teeth 2332 extending around the perimeter of
the central body 2335. The articulation drive 6330 comprises an
annular array of drive teeth 6332 which is meshingly engaged with
the stationary teeth 2332. When the articulation drive 6330 is
rotated, the articulation drive 6330 pushes against the stationary
gear 2330 and articulates the distal attachment portion 2400 of the
shaft assembly 2000 and the end effector 7000 about the
articulation joint 2300.
[0286] Referring primarily to FIG. 32, the third clutch system 6300
comprises a third clutch 6310, an expandable third drive ring 6320,
and a third electromagnetic actuator 6340. The third clutch 6310
comprises an annular ring and is slideably disposed on the drive
shaft 2730. The third clutch 6310 is comprised of a magnetic
material and is movable between a disengaged, or unactuated,
position (FIG. 32) and an engaged, or actuated, position (FIG. 33)
by electromagnetic fields EF generated by the third electromagnetic
actuator 6340. In various instances, the third clutch 6310 is at
least partially comprised of iron and/or nickel, for example. In at
least one instance, the third clutch 6310 comprises a permanent
magnet. As illustrated in FIG. 22A, the drive shaft 2730 comprises
one or more longitudinal key slots 6315 defined therein which are
configured to constrain the longitudinal movement of the third
clutch 6310 relative to the drive shaft 2730. More specifically,
the third clutch 6310 comprises one or more keys extending into the
key slots 6315 such that the distal ends of the key slots 6315 stop
the distal movement of the third clutch 6310 and the proximal ends
of the key slots 6315 stop the proximal movement of the third
clutch 6310.
[0287] When the third clutch 6310 is in its disengaged position,
referring to FIG. 32, the third clutch 6310 rotates with the drive
shaft 2730 but does not transmit rotational motion to the third
drive ring 6320. As can be seen in FIG. 32, the third clutch 6310
is separated from, or not in contact with, the third drive ring
6320. As a result, the rotation of the drive shaft 2730 and the
third clutch 6310 is not transmitted to the articulation drive 6330
when the third clutch assembly 6300 is in its disengaged state.
When the third clutch 6310 is in its engaged position, referring to
FIG. 33, the third clutch 6310 is engaged with the third drive ring
6320 such that the third drive ring 6320 is expanded, or stretched,
radially outwardly into contact with the articulation drive 6330.
In at least one instance, the third drive ring 6320 comprises an
elastomeric band, for example. As can be seen in FIG. 33, the third
drive ring 6320 is compressed against an annular inner sidewall
6335 of the articulation drive 6330. As a result, the rotation of
the drive shaft 2730 and the third clutch 6310 is transmitted to
the articulation drive 6330 when the third clutch assembly 6300 is
in its engaged state. Depending on the direction in which the drive
shaft 2730 is rotated, the third clutch assembly 6300 can
articulate the distal attachment portion 2400 of the shaft assembly
2000 and the end effector 7000 in a first or second direction about
the articulation joint 2300.
[0288] As described above, the third electromagnetic actuator 6340
is configured to generate magnetic fields to move the third clutch
6310 between its disengaged (FIG. 32) and engaged (FIG. 33)
positions. For instance, referring to FIG. 32, the third
electromagnetic actuator 6340 is configured to emit a magnetic
field EF.sub.L which repulses, or drives, the third clutch 6310
away from the third drive ring 6320 when the third clutch assembly
6300 is in its disengaged state. The third electromagnetic actuator
6340 comprises one or more wound coils in a cavity defined in the
shaft frame 2530 which generate the magnetic field EF.sub.L when
current flows in a first direction through a third electrical
clutch circuit including the wound coils. The control system 1800
is configured to apply a first voltage polarity to the third
electrical clutch circuit to create the current flowing in the
first direction. The control system 1800 can continuously apply the
first voltage polarity to the third electric clutch circuit to
continuously hold the third clutch 6310 in its disengaged position.
While such an arrangement can prevent the third clutch 6310 from
unintentionally engaging the third drive ring 6320, such an
arrangement can also consume a lot of power. Alternatively, the
control system 1800 can apply the first voltage polarity to the
third electrical clutch circuit for a sufficient period of time to
position the third clutch 6310 in its disengaged position and then
discontinue applying the first voltage polarity to the third
electric clutch circuit, thereby resulting in a lower consumption
of power.
[0289] Further to the above, the third electromagnetic actuator
6340 is configured to emit a magnetic field EF.sub.D which pulls,
or drives, the third clutch 6310 toward the third drive ring 6320
when the third clutch assembly 6300 is in its engaged state. The
coils of the third electromagnetic actuator 6340 generate the
magnetic field EF.sub.D when current flows in a second, or
opposite, direction through the third electrical clutch circuit.
The control system 1800 is configured to apply an opposite voltage
polarity to the third electrical shaft circuit to create the
current flowing in the opposite direction. The control system 1800
can continuously apply the opposite voltage polarity to the third
electric shaft circuit to continuously hold the third clutch 6310
in its engaged position and maintain the operable engagement
between the third drive ring 6320 and the articulation drive 6330.
Alternatively, the third clutch 6210 can be configured to become
wedged within the third drive ring 6320 when the third clutch 6310
is in its engaged position and, in such instances, the control
system 1800 may not need to continuously apply a voltage polarity
to the third shaft electrical circuit to hold the third clutch
assembly 6300 in its engaged state. In such instances, the control
system 1800 can discontinue applying the voltage polarity once the
third clutch 6310 has been sufficiently wedged in the third drive
ring 6320. In any event, the end effector 7000 is articulatable in
a first direction or a second direction, depending on the direction
in which the drive shaft 2730 is rotated, when the third clutch
assembly 6300 is in its engaged state.
[0290] Further to the above, referring to FIGS. 22, 32, and 33, the
articulation drive system further comprises a lockout 6350 which
prevents, or at least inhibits, the articulation of the distal
attachment portion 2400 of the shaft assembly 2000 and the end
effector 7000 about the articulation joint 2300 when the third
clutch 6310 is in its disengaged position (FIG. 32). Referring
primarily to FIG. 22, the articulation link 2340 comprises a slot,
or groove, 2350 defined therein wherein the lockout 6350 is
slideably positioned in the slot 2350 and extends at least
partially under the stationary articulation gear 2330. The lockout
6350 comprises at attachment hook 6352 engaged with the third
clutch 6310. More specifically, the third clutch 6310 comprises an
annular slot, or groove, 6312 defined therein and the attachment
hook 6352 is positioned in the annular slot 6312 such that the
lockout 6350 translates with the third clutch 6310. Notably,
however, the lockout 6350 does not rotate, or at least
substantially rotate, with the third clutch 6310. Instead, the
annular groove 6312 in the third clutch 6310 permits the third
clutch 6310 to rotate relative to the lockout 6350. The lockout
6350 further comprises a lockout hook 6354 slideably positioned in
a radially-extending lockout slot 2334 defined in the bottom of the
stationary gear 2330. When the third clutch 6310 is in its
disengaged position, as illustrated in FIG. 32, the lockout 6350 is
in a locked position in which the lockout hook 6354 prevents the
end effector 7000 from rotating about the articulation joint 2300.
When the third clutch 6310 is in its engaged position, as
illustrated in FIG. 33, the lockout 6350 is in an unlocked position
in which the lockout hook 6354 is no longer positioned in the
lockout slot 2334. Instead, the lockout hook 6354 is positioned in
a clearance slot defined in the middle or body 2335 of the
stationary gear 2330. In such instances, the lockout hook 6354 can
rotate within the clearance slot when the end effector 7000 rotates
about the articulation joint 2300.
[0291] Further to the above, the radially-extending lockout slot
2334 depicted in FIGS. 32 and 33 extends longitudinally, i.e.,
along an axis which is parallel to the longitudinal axis of the
elongate shaft 2200. Once the end effector 7000 has been
articulated, however, the lockout hook 6354 is no longer aligned
with the longitudinal lockout slot 2334. With this in mind, the
stationary gear 2330 comprises a plurality, or an array, of
radially-extending lockout slots 2334 defined in the bottom of the
stationary gear 2330 such that, when the third clutch 6310 is
deactuated and the lockout 6350 is pulled distally after the end
effector 7000 has been articulated, the lockout hook 6354 can enter
one of the lockout slots 2334 and lock the end effector 7000 in its
articulated position. Thus, as a result, the end effector 7000 can
be locked in an unarticulated and an articulated position. In
various instances, the lockout slots 2334 can define discrete
articulated positions for the end effector 7000. For instance, the
lockout slots 2334 can be defined at 10 degree intervals, for
example, which can define discrete articulation orientations for
the end effector 7000 at 10 degree intervals. In other instances,
these orientations can be at 5 degree intervals, for example. In
alternative embodiments, the lockout 6350 comprises a brake that
engages a circumferential shoulder defined in the stationary gear
2330 when the third clutch 6310 is disengaged from the third drive
ring 6320. In such an embodiment, the end effector 7000 can be
locked in any suitable orientation. In any event, the lockout 6350
prevents, or at least reduces the possibility of, the end effector
7000 unintentionally articulating. As a result of the above, the
third clutch 6310 can do things--operate the articulation drive
when it is in its engaged position and lock out the articulation
drive when it is in its disengaged position.
[0292] Referring primarily to FIGS. 24 and 25, the shaft frame 2530
and the drive shaft 2730 extend through the articulation joint 2300
into the distal attachment portion 2400. When the end effector 7000
is articulated, as illustrated in FIGS. 16 and 17, the shaft frame
2530 and the drive shaft 2730 bend to accommodate the articulation
of the end effector 7000. Thus, the shaft frame 2530 and the drive
shaft 2730 are comprised of any suitable material which
accommodates the articulation of the end effector 7000. Moreover,
as discussed above, the shaft frame 2530 houses the first, second,
and third electromagnetic actuators 6140, 6240, and 6340. In
various instances, the first, second, and third electromagnetic
actuators 6140, 6240, and 6340 each comprise wound wire coils, such
as copper wire coils, for example, and the shaft frame 2530 is
comprised of an insulative material to prevent, or at least reduce
the possibility of, short circuits between the first, second, and
third electromagnetic actuators 6140, 6240, and 6340. In various
instances, the first, second, and third electrical clutch circuits
extending through the shaft frame 2530 are comprised of insulated
electrical wires, for example. Further to the above, the first,
second, and third electrical clutch circuits place the
electromagnetic actuators 6140, 6240, and 6340 in communication
with the control system 1800 in the drive module 1100.
[0293] As described above, the clutches 6110, 6210, and/or 6310 can
be held in their disengaged positions so that they do not
unintentionally move into their engaged positions. In various
arrangements, the clutch system 6000 comprises a first biasing
member, such as a spring, for example, configured to bias the first
clutch 6110 into its disengaged position, a second biasing member,
such as a spring, for example, configured to bias the second clutch
6210 into its disengaged position, and/or a third biasing member,
such as a spring, for example, configured to bias the third clutch
6110 into its disengaged position. In such arrangements, the
biasing forces of the springs can be selectively overcome by the
electromagnetic forces generated by the electromagnetic actuators
when energized by an electrical current. Further to the above, the
clutches 6110, 6210, and/or 6310 can be retained in their engaged
positions by the drive rings 6120, 6220, and/or 6320, respectively.
More specifically, in at least one instance, the drive rings 6120,
6220, and/or 6320 are comprised of an elastic material which grips
or frictionally holds the clutches 6110, 6210, and/or 6310,
respectively, in their engaged positions. In various alternative
embodiments, the clutch system 6000 comprises a first biasing
member, such as a spring, for example, configured to bias the first
clutch 6110 into its engaged position, a second biasing member,
such as a spring, for example, configured to bias the second clutch
6210 into its engaged position, and/or a third biasing member, such
as a spring, for example, configured to bias the third clutch 6110
into its engaged position. In such arrangements, the biasing forces
of the springs can be overcome by the electromagnetic forces
applied by the electromagnetic actuators 6140, 6240, and/or 6340,
respectively, as needed to selectively hold the clutches 6110,
6210, and 6310 in their disengaged positions. In any one
operational mode of the surgical system, the control assembly 1800
can energize one of the electromagnetic actuators to engage one of
the clutches while energizing the other two electromagnetic
actuators to disengage the other two clutches.
[0294] Although the clutch system 6000 comprises three clutches to
control three drive systems of the surgical system, a clutch system
can comprise any suitable number of clutches to control any
suitable number of systems. Moreover, although the clutches of the
clutch system 6000 slide proximally and distally between their
engaged and disengaged positions, the clutches of a clutch system
can move in any suitable manner. In addition, although the clutches
of the clutch system 6000 are engaged one at a time to control one
drive motion at a time, various instances are envisioned in which
more than one clutch can be engaged to control more than one drive
motion at a time.
[0295] In view of the above, the reader should appreciate that the
control system 1800 is configured to, one, operate the motor system
1600 to rotate the drive shaft system 2700 in an appropriate
direction and, two, operate the clutch system 6000 to transfer the
rotation of the drive shaft system 2700 to the appropriate function
of the end effector 7000. Moreover, as discussed above, the control
system 1800 is responsive to inputs from the clamping trigger
system 2600 of the shaft assembly 2000 and the input system 1400 of
the handle 1000. When the clamping trigger system 2600 is actuated,
as discussed above, the control system 1800 activates the first
clutch assembly 6100 and deactivates the second clutch assembly
6200 and the third clutch assembly 6300. In such instances, the
control system 1800 also supplies power to the motor system 1600 to
rotate the drive shaft system 2700 in a first direction to clamp
the jaw assembly 7100 of the end effector 7000. When the control
system 1800 detects that the jaw assembly 7100 is in its clamped
configuration, the control system 1800 stops the motor assembly
1600 and deactivates the first clutch assembly 6100. When the
control system 1800 detects that the clamping trigger system 2600
has been moved to, or is being moved to, its unactuated position,
the control system 1800 activates, or maintains the activation of,
the first clutch assembly 6100 and deactivates, or maintains the
deactivation of, the second clutch assembly 6200 and the third
clutch assembly 6300. In such instances, the control system 1800
also supplies power to the motor system 1600 to rotate the drive
shaft system 2700 in a second direction to open the jaw assembly
7100 of the end effector 7000.
[0296] When the rotation actuator 1420 is actuated in a first
direction, further to the above, the control system 1800 activates
the second clutch assembly 6200 and deactivates the first clutch
assembly 6100 and the third clutch assembly 6300. In such
instances, the control system 1800 also supplies power to the motor
system 1600 to rotate the drive shaft system 2700 in a first
direction to rotate the end effector 7000 in a first direction.
When the control system 1800 detects that the rotation actuator
1420 has been actuated in a second direction, the control system
1800 activates, or maintains the activation of, the second clutch
assembly 6200 and deactivates, or maintains the deactivation of,
the first clutch assembly 6100 and the third clutch assembly 6300.
In such instances, the control system 1800 also supplies power to
the motor system 1600 to rotate the drive shaft system 2700 in a
second direction to rotate the drive shaft system 2700 in a second
direction to rotate the end effector 7000 in a second direction.
When the control system 1800 detects that the rotation actuator
1420 is not actuated, the control system 1800 deactivates the
second clutch assembly 6200.
[0297] When the first articulation actuator 1432 is depressed,
further to the above, the control system 1800 activates the third
clutch assembly 6300 and deactivates the first clutch assembly 6100
and the second clutch assembly 6200. In such instances, the control
system 1800 also supplies power to the motor system 1600 to rotate
the drive shaft system 2700 in a first direction to articulate the
end effector 7000 in a first direction. When the control system
1800 detects that the second articulation actuator 1434 is
depressed, the control system 1800 activates, or maintains the
activation of, the third clutch assembly 6200 and deactivates, or
maintains the deactivation of, the first clutch assembly 6100 and
the second clutch assembly 6200. In such instances, the control
system 1800 also supplies power to the motor system 1600 to rotate
the drive shaft system 2700 in a second direction to articulate the
end effector 7000 in a second direction. When the control system
1800 detects that neither the first articulation actuator 1432 nor
the second articulation actuator 1434 are actuated, the control
system 1800 deactivates the third clutch assembly 6200.
[0298] Further to the above, the control system 1800 is configured
to change the operating mode of the stapling system based on the
inputs it receives from the clamping trigger system 2600 of the
shaft assembly 2000 and the input system 1400 of the handle 1000.
The control system 1800 is configured to shift the clutch system
6000 before rotating the shaft drive system 2700 to perform the
corresponding end effector function. Moreover, the control system
1800 is configured to stop the rotation of the shaft drive system
2700 before shifting the clutch system 6000. Such an arrangement
can prevent the sudden movements in the end effector 7000.
Alternatively, the control system 1800 can shift the clutch system
600 while the shaft drive system 2700 is rotating. Such an
arrangement can allow the control system 1800 to shift quickly
between operating modes.
[0299] As discussed above, referring to FIG. 34, the distal
attachment portion 2400 of the shaft assembly 2000 comprises an end
effector lock 6400 configured to prevent the end effector 7000 from
being unintentionally decoupled from the shaft assembly 2000. The
end effector lock 6400 comprises a lock end 6410 selectively
engageable with the annular array of lock notches 7410 defined on
the proximal attachment portion 7400 of the end effector 7000, a
proximal end 6420, and a pivot 6430 rotatably connecting the end
effector lock 6400 to the articulation link 2320. When the third
clutch 6310 of the third clutch assembly 6300 is in its disengaged
position, as illustrated in FIG. 34, the third clutch 6310 is
contact with the proximal end 6420 of the end effector lock 6400
such that the lock end 6410 of the end effector lock 6400 is
engaged with the array of lock notches 7410. In such instances, the
end effector 7000 can rotate relative to the end effector lock 6400
but cannot translate relative to the distal attachment portion
2400. When the third clutch 6310 is moved into its engaged
position, as illustrated in FIG. 35, the third clutch 6310 is no
longer engaged with the proximal end 6420 of the end effector lock
6400. In such instances, the end effector lock 6400 is free to
pivot upwardly and permit the end effector 7000 to be detached from
the shaft assembly 2000.
[0300] The above being said, referring again to FIG. 34, it is
possible that the second clutch 6210 of the second clutch assembly
6200 is in its disengaged position when the clinician detaches, or
attempts to detach, the end effector 7000 from the shaft assembly
2000. As discussed above, the second clutch 6210 is engaged with
the second clutch lock 6250 when the second clutch 6210 is in its
disengaged position and, in such instances, the second clutch lock
6250 is pushed into engagement with the articulation link 2340.
More specifically, the second clutch lock 6250 is positioned in the
channel 2345 defined in the articulation 2340 when the second
clutch 6210 is engaged with the second clutch lock 6250 which may
prevent, or at least impede, the end effector 7000 from being
detached from the shaft assembly 2000. To facilitate the release of
the end effector 7000 from the shaft assembly 2000, the control
system 1800 can move the second clutch 6210 into its engaged
position in addition to moving the third clutch 6310 into its
engaged position. In such instances, the end effector 7000 can
clear both the end effector lock 6400 and the second clutch lock
6250 when the end effector 7000 is removed.
[0301] In at least one instance, further to the above, the drive
module 1100 comprises an input switch and/or sensor in
communication with the control system 1800 via the input system
1400, and/or the control system 1800 directly, which, when
actuated, causes the control system 1800 to unlock the end effector
7000. In various instances, the drive module 1100 comprises an
input screen 1440 in communication with the board 1410 of the input
system 1400 which is configured to receive an unlock input from the
clinician. In response to the unlock input, the control system 1800
can stop the motor system 1600, if it is running, and unlock the
end effector 7000 as described above. The input screen 1440 is also
configured to receive a lock input from the clinician in which the
input system 1800 moves the second clutch assembly 6200 and/or the
third clutch assembly 6300 into their unactuated states to lock the
end effector 7000 to the shaft assembly 2000.
[0302] FIG. 37 depicts a shaft assembly 2000' in accordance with at
least one alternative embodiment. The shaft assembly 2000' is
similar to the shaft assembly 2000 in many respects, most of which
will not be repeated herein for the sake of brevity. Similar to the
shaft assembly 2000, the shaft assembly 2000' comprises a shaft
frame, i.e., shaft frame 2530'. The shaft frame 2530' comprises a
longitudinal passage 2535' and, in addition, a plurality of clutch
position sensors, i.e., a first sensor 6180', a second sensor
6280', and a third sensor 6380' positioned in the shaft frame
2530'. The first sensor 6180' is in signal communication with the
control system 1800 as part of a first sensing circuit. The first
sensing circuit comprises signal wires extending through the
longitudinal passage 2535'; however, the first sensing circuit can
comprise a wireless signal transmitter and receiver to place the
first sensor 6180' in signal communication with the control system
1800. The first sensor 6180' is positioned and arranged to detect
the position of the first clutch 6110 of the first clutch assembly
6100. Based on data received from the first sensor 6180', the
control system 1800 can determine whether the first clutch 6110 is
in its engaged position, its disengaged position, or somewhere
in-between. With this information, the control system 1800 can
assess whether or not the first clutch 6110 is in the correct
position given the operating state of the surgical instrument. For
instance, if the surgical instrument is in its jaw clamping/opening
operating state, the control system 1800 can verify whether the
first clutch 6110 is properly positioned in its engaged position.
In such instances, further to the below, the control system 1800
can also verify that the second clutch 6210 is in its disengaged
position via the second sensor 6280' and that the third clutch 6310
is in its disengaged position via the third sensor 6380'.
Correspondingly, the control system 1800 can verify whether the
first clutch 6110 is properly positioned in its disengaged position
if the surgical instrument is not in its jaw clamping/opening
state. To the extent that the first clutch 6110 is not in its
proper position, the control system 1800 can actuate the first
electromagnetic actuator 6140 in an attempt to properly position
the first clutch 6110. Likewise, the control system 1800 can
actuate the electromagnetic actuators 6240 and/or 6340 to properly
position the clutches 6210 and/or 6310, if necessary.
[0303] The second sensor 6280' is in signal communication with the
control system 1800 as part of a second sensing circuit. The second
sensing circuit comprises signal wires extending through the
longitudinal passage 2535'; however, the second sensing circuit can
comprise a wireless signal transmitter and receiver to place the
second sensor 6280' in signal communication with the control system
1800. The second sensor 6280' is positioned and arranged to detect
the position of the second clutch 6210 of the first clutch assembly
6200. Based on data received from the second sensor 6280', the
control system 1800 can determine whether the second clutch 6210 is
in its engaged position, its disengaged position, or somewhere
in-between. With this information, the control system 1800 can
assess whether or not the second clutch 6210 is in the correct
position given the operating state of the surgical instrument. For
instance, if the surgical instrument is in its end effector
rotation operating state, the control system 1800 can verify
whether the second clutch 6210 is properly positioned in its
engaged position. In such instances, the control system 1800 can
also verify that the first clutch 6110 is in its disengaged
position via the first sensor 6180' and, further to the below, the
control system 1800 can also verify that the third clutch 6310 is
in its disengaged position via the third sensor 6380'.
Correspondingly, the control system 1800 can verify whether the
second clutch 6110 is properly positioned in its disengaged
position if the surgical instrument is not in its end effector
rotation state. To the extent that the second clutch 6210 is not in
its proper position, the control system 1800 can actuate the second
electromagnetic actuator 6240 in an attempt to properly position
the second clutch 6210. Likewise, the control system 1800 can
actuate the electromagnetic actuators 6140 and/or 6340 to properly
position the clutches 6110 and/or 6310, if necessary.
[0304] The third sensor 6380' is in signal communication with the
control system 1800 as part of a third sensing circuit. The third
sensing circuit comprises signal wires extending through the
longitudinal passage 2535'; however, the third sensing circuit can
comprise a wireless signal transmitter and receiver to place the
third sensor 6380' in signal communication with the control system
1800. The third sensor 6380' is positioned and arranged to detect
the position of the third clutch 6310 of the third clutch assembly
6300. Based on data received from the third sensor 6380', the
control system 1800 can determine whether the third clutch 6310 is
in its engaged position, its disengaged position, or somewhere
in-between. With this information, the control system 1800 can
assess whether or not the third clutch 6310 is in the correct
position given the operating state of the surgical instrument. For
instance, if the surgical instrument is in its end effector
articulation operating state, the control system 1800 can verify
whether the third clutch 6310 is properly positioned in its engaged
position. In such instances, the control system 1800 can also
verify that the first clutch 6110 is in its disengaged position via
the first sensor 6180' and that the second clutch 6210 is in its
disengaged position via the second sensor 6280'. Correspondingly,
the control system 1800 can verify whether the third clutch 6310 is
properly positioned in its disengaged position if the surgical
instrument is not in its end effector articulation state. To the
extent that the third clutch 6310 is not in its proper position,
the control system 1800 can actuate the third electromagnetic
actuator 6340 in an attempt to properly position the third clutch
6310. Likewise, the control system 1800 can actuate the
electromagnetic actuators 6140 and/or 6240 to properly position the
clutches 6110 and/or 6210, if necessary.
[0305] Further to the above, the clutch position sensors, i.e., the
first sensor 6180', the second sensor 6280', and the third sensor
6380' can comprise any suitable type of sensor. In various
instances, the first sensor 6180', the second sensor 6280', and the
third sensor 6380' each comprise a proximity sensor. In such an
arrangement, the sensors 6180', 6280', and 6380' are configured to
detect whether or not the clutches 6110, 6210, and 6310,
respectively, are in their engaged positions. In various instances,
the first sensor 6180', the second sensor 6280', and the third
sensor 6380' each comprise a Hall Effect sensor, for example. In
such an arrangement, the sensors 6180', 6280', and 6380' can not
only detect whether or not the clutches 6110, 6210, and 6310,
respectively, are in their engaged positions but the sensors 6180',
6280', and 6380' can also detect how close the clutches 6110, 6210,
and 6310 are with respect to their engaged or disengaged
positions.
[0306] FIG. 38 depicts the shaft assembly 2000' and an end effector
7000'' in accordance with at least one alternative embodiment. The
end effector 7000'' is similar to the end effector 7000 in many
respects, most of which will not be repeated herein for the sake of
brevity. Similar to the end effector 7000, the shaft assembly
7000'' comprises a jaw assembly 7100 and a jaw assembly drive
configured to move the jaw assembly 7100 between its open and
closed configurations. The jaw assembly drive comprises drive links
7140, a drive nut 7150'', and a drive screw 6130''. The drive nut
7150'' comprises a sensor 7190'' positioned therein which is
configured to detect the position of a magnetic element 6190''
positioned in the drive screw 6130''. The magnetic element 6190''
is positioned in an elongate aperture 6134'' defined in the drive
screw 6130'' and can comprise a permanent magnet and/or can be
comprised of iron, nickel, and/or any suitable metal, for example.
In various instances, the sensor 7190'' comprises a proximity
sensor, for example, which is in signal communication with the
control system 1800. In certain instances, the sensor 7190''
comprises a Hall Effect sensor, for example, in signal
communication with the control system 1800. In certain instances,
the sensor 7190'' comprises an optical sensor, for example, and the
detectable element 6190'' comprises an optically detectable
element, such as a reflective element, for example. In either
event, the sensor 7190'' is configured to communicate wirelessly
with the control system 1800 via a wireless signal transmitter and
receiver and/or via a wired connection extending through the shaft
frame passage 2532', for example.
[0307] The sensor 7190'', further to the above, is configured to
detect when the magnetic element 6190'' is adjacent to the sensor
7190'' such that the control system 1800 can use this data to
determine that the jaw assembly 7100 has reached the end of its
clamping stroke. At such point, the control system 1800 can stop
the motor assembly 1600. The sensor 7190'' and the control system
1800 are also configured to determine the distance between where
the drive screw 6130'' is currently positioned and where the drive
screw 6130'' should be positioned at the end of its closure stroke
in order to calculate the amount of closure stroke of the drive
screw 6130'' that is still needed to close the jaw assembly 7100.
Moreover, such information can be used by the control system 1800
to assess the current configuration of the jaw assembly 7100, i.e.,
whether the jaw assembly 7100 is in its open configuration, its
closed configuration, or a partially closed configuration. The
sensor system could be used to determine when the jaw assembly 7100
has reached its fully open position and stop the motor assembly
1600 at that point. In various instances, the control system 1800
could use this sensor system to confirm that the first clutch
assembly 6100 is in its actuated state by confirming that the jaw
assembly 7100 is moving while the motor assembly 1600 is turning.
Similarly, the control system 1800 could use this sensor system to
confirm that the first clutch assembly 6100 is in its unactuated
state by confirming that the jaw assembly 7100 is not moving while
the motor assembly 1600 is turning.
[0308] FIG. 39 depicts a shaft assembly 2000''' and an end effector
7000''' in accordance with at least one alternative embodiment. The
shaft assembly 2000''' is similar to the shaft assemblies 2000 and
2000' in many respects, most of which will not be repeated herein
for the sake of brevity. The end effector 7000''' is similar to the
end effectors 7000 and 7000'' in many respects, most of which will
not be repeated herein for the sake of brevity. Similar to the end
effector 7000, the end effector 7000''' comprises a jaw assembly
7100 and a jaw assembly drive configured to move the jaw assembly
7100 between its open and closed configurations and, in addition,
an end effector rotation drive that rotates the end effector
7000''' relative to the distal attachment portion 2400 of the shaft
assembly 2000'. The end effector rotation drive comprises an outer
housing 6230''' that is rotated relative to a shaft frame 2530'''
of the end effector 7000''' by the second clutch assembly 6200. The
shaft frame 2530''' comprises a sensor 6290''' positioned therein
which is configured to detect the position of a magnetic element
6190''' positioned in and/or on the outer housing 6230'''. The
magnetic element 6190''' can comprise a permanent magnet and/or can
be comprised of iron, nickel, and/or any suitable metal, for
example. In various instances, the sensor 6290''' comprises a
proximity sensor, for example, in signal communication with the
control system 1800. In certain instances, the sensor 6290'''
comprises a Hall Effect sensor, for example, in signal
communication with the control system 1800. In either event, the
sensor 6290''' is configured to communicate wirelessly with the
control system 1800 via a wireless signal transmitter and receiver
and/or via a wired connection extending through the shaft frame
passage 2532', for example. In various instances, the control
system 1800 can use the sensor 6290''' to confirm whether the
magnetic element 6190''' is rotating and, thus, confirm that the
second clutch assembly 6200 is in its actuated state. Similarly,
the control system 1800 can use the sensor 6290''' to confirm
whether the magnetic element 6190''' is not rotating and, thus,
confirm that the second clutch assembly 6200 is in its unactuated
state. The control system 1800 can also use the sensor 6290''' to
confirm that the second clutch assembly 6200 is in its unactuated
state by confirming that the second clutch 6210 is positioned
adjacent the sensor 6290'''.
[0309] FIG. 40 depicts a shaft assembly 2000'''' in accordance with
at least one alternative embodiment. The shaft assembly 2000'''' is
similar to the shaft assemblies 2000, 2000', and 2000''' in many
respects, most of which will not be repeated herein for the sake of
brevity. Similar to the shaft assembly 2000, the shaft assembly
2000'''' comprises, among other things, an elongate shaft 2200, an
articulation joint 2300, and a distal attachment portion 2400
configured to receive an end effector, such as end effector 7000',
for example. Similar to the shaft assembly 2000, the shaft assembly
2000'''' comprises an articulation drive, i.e., articulation drive
6330'''' configured to rotate the distal attachment portion 2400
and the end effector 7000' about the articulation joint 2300.
Similar to the above, a shaft frame 2530'''' comprises a sensor
positioned therein configured to detect the position, and/or
rotation, of a magnetic element 6390'''' positioned in and/or on
the articulation drive 6330''''. The magnetic element 6390'''' can
comprise a permanent magnet and/or can be comprised of iron,
nickel, and/or any suitable metal, for example. In various
instances, the sensor comprises a proximity sensor, for example, in
signal communication with the control system 1800. In certain
instances, the sensor comprises a Hall Effect sensor, for example,
in signal communication with the control system 1800. In either
event, the sensor is configured to communicate wirelessly with the
control system 1800 via a wireless signal transmitter and receiver
and/or via a wired connection extending through the shaft frame
passage 2532', for example. In various instances, the control
system 1800 can use the sensor to confirm whether the magnetic
element 6390'''' is rotating and, thus, confirm that the third
clutch assembly 6300 is in its actuated state. Similarly, the
control system 1800 can use the sensor to confirm whether the
magnetic element 6390'''' is not rotating and, thus, confirm that
the third clutch assembly 6300 is in its unactuated state. In
certain instances, the control system 1800 can use the sensor to
confirm that the third clutch assembly 6300 is in its unactuated
state by confirming that the third clutch 6310 is positioned
adjacent the sensor.
[0310] Referring to FIG. 40 once again, the shaft assembly 2000''''
comprises an end effector lock 6400' configured to releasably lock
the end effector 7000', for example, to the shaft assembly
2000''''. The end effector lock 6400' is similar to the end
effector lock 6400 in many respects, most of which will not be
discussed herein for the sake of brevity. Notably, though, a
proximal end 6420' of the lock 6400' comprises a tooth 6422'
configured to engage the annular slot 6312 of the third clutch 6310
and releasably hold the third clutch 6310 in its disengaged
position. That said, the actuation of the third electromagnetic
assembly 6340 can disengage the third clutch 6310 from the end
effector lock 6400'. Moreover, in such instances, the proximal
movement of the third clutch 6310 into its engaged position rotates
the end effector lock 6400' into a locked position and into
engagement with the lock notches 7410 to lock the end effector
7000' to the shaft assembly 2000''''. Correspondingly, the distal
movement of the third clutch 6310 into its disengaged position
unlocks the end effector 7000' and allows the end effector 7000' to
be disassembled from the shaft assembly 2000''''.
[0311] Further to the above, an instrument system including a
handle and a shaft assembly attached thereto can be configured to
perform a diagnostic check to assess the state of the clutch
assemblies 6100, 6200, and 6300. In at least one instance, the
control system 1800 sequentially actuates the electromagnetic
actuators 6140, 6240, and/or 6340--in any suitable order--to verify
the positions of the clutches 6110, 6210, and/or 6310,
respectively, and/or verify that the clutches are responsive to the
electromagnetic actuators and, thus, not stuck. The control system
1800 can use sensors, including any of the sensors disclosed
herein, to verify the movement of the clutches 6110, 6120, and 6130
in response to the electromagnetic fields created by the
electromagnetic actuators 6140, 6240, and/or 6340. In addition, the
diagnostic check can also include verifying the motions of the
drive systems. In at least one instance, the control system 1800
sequentially actuates the electromagnetic actuators 6140, 6240,
and/or 6340--in any suitable order--to verify that the jaw drive
opens and/or closes the jaw assembly 7100, the rotation drive
rotates the end effector 7000, and/or the articulation drive
articulates the end effector 7000, for example. The control system
1800 can use sensors to verify the motions of the jaw assembly 7100
and end effector 7000.
[0312] The control system 1800 can perform the diagnostic test at
any suitable time, such as when a shaft assembly is attached to the
handle and/or when the handle is powered on, for example. If the
control system 1800 determines that the instrument system passed
the diagnostic test, the control system 1800 can permit the
ordinary operation of the instrument system. In at least one
instance, the handle can comprise an indicator, such as a green
LED, for example, which indicates that the diagnostic check has
been passed. If the control system 1800 determines that the
instrument system failed the diagnostic test, the control system
1800 can prevent and/or modify the operation of the instrument
system. In at least one instance, the control system 1800 can limit
the functionality of the instrument system to only the functions
necessary to remove the instrument system from the patient, such as
straightening the end effector 7000 and/or opening and closing the
jaw assembly 7100, for example. In at least one respect, the
control system 1800 enters into a limp mode. The limp mode of the
control system 1800 can reduce a current rotational speed of the
motor 1610 by any percentage selected from a range of about 75% to
about 25%, for example. In one example, the limp mode reduces a
current rotational speed of the motor 1610 by 50%. In one example,
the limp mode reduces the current rotational speed of the motor
1610 by 75%. The limp mode may cause a current torque of the motor
1610 to be reduced by any percentage selected from a range of about
75% to about 25%, for example. In one example, the limp mode
reduces a current torque of the motor 1610 by 50%. The handle can
comprise an indicator, such as a red LED, for example, which
indicates that the instrument system failed the diagnostic check
and/or that the instrument system has entered into a limp mode. The
above being said, any suitable feedback can be used to warn the
clinician that the instrument system is not operating properly such
as, for example, an audible warning and/or a tactile or vibratory
warning, for example.
[0313] FIGS. 41-43 depict a clutch system 6000' in accordance with
at least one alternative embodiment. The clutch system 6000' is
similar to the clutch system 6000 in many respects, most of which
will not be repeated herein for the sake of brevity. Similar to the
clutch system 6000, the clutch system 6000' comprises a clutch
assembly 6100' which is actuatable to selectively couple a
rotatable drive input 6030' with a rotatable drive output 6130'.
The clutch assembly 6100' comprises clutch plates 6110' and drive
rings 6120'. The clutch plates 6110' are comprised of a magnetic
material, such as iron and/or nickel, for example, and can comprise
a permanent magnet. As described in greater detail below, the
clutch plates 6110' are movable between unactuated positions (FIG.
42) and actuated positions (FIG. 43) within the drive output 6130'.
The clutch plates 6110' are slideably positioned in apertures
defined in the drive output 6130' such that the clutch plates 6110'
rotate with the drive output 6130' regardless of whether the clutch
plates 6110' are in their unactuated or actuated positions.
[0314] When the clutch plates 6110' are in their unactuated
positions, as illustrated in FIG. 42, the rotation of the drive
input 6030' is not transferred to the drive output 6130'. More
specifically, when the drive input 6030' is rotated, in such
instances, the drive input 6030' slides past and rotates relative
to the drive rings 6120' and, as a result, the drive rings 6120' do
not drive the clutch plates 6110' and the drive output 6130'. When
the clutch plates 6110' are in their actuated positions, as
illustrated in FIG. 43, the clutch plates 6110' resiliently
compress the drive rings 6120' against the drive input 6030'. The
drive rings 6120' are comprised of any suitable compressible
material, such as rubber, for example. In any event, in such
instances, the rotation of the drive input 6030' is transferred to
the drive output 6130' via the drive rings 6120' and the clutch
plates 6110'. The clutch system 6000' comprises a clutch actuator
6140' configured to move the clutch plates 6110' into their
actuated positions. The clutch actuator 6140' is comprised of a
magnetic material such as iron and/or nickel, for example, and can
comprise a permanent magnet. The clutch actuator 6140' is slideably
positioned in a longitudinal shaft frame 6050' extending through
the drive input 6030' and can be moved between an unactuated
position (FIG. 42) and an actuated position (FIG. 43) by a clutch
shaft 6060'. In at least one instance, the clutch shaft 6060'
comprises a polymer cable, for example. When the clutch actuator
6140' is in its actuated position, as illustrated in FIG. 43, the
clutch actuator 6140' pulls the clutch plates 6110' inwardly to
compress the drive rings 6120', as discussed above. When the clutch
actuator 6140' is moved into its unactuated position, as
illustrated in FIG. 42, the drive rings 6120' resiliently expand
and push the clutch plates 6110' away from the drive input 6030'.
In various alternative embodiments, the clutch actuator 6140' can
comprise an electromagnet. In such an arrangement, the clutch
actuator 6140' can be actuated by an electrical circuit extending
through a longitudinal aperture defined in the clutch shaft 6060',
for example. In various instances, the clutch system 6000' further
comprises electrical wires 6040', for example, extending through
the longitudinal aperture.
[0315] FIG. 44 depicts an end effector 7000a including a jaw
assembly 7100a, a jaw assembly drive, and a clutch system 6000a in
accordance with at least one alternative embodiment. The jaw
assembly 7100a comprises a first jaw 7110a and a second jaw 7120a
which are selectively rotatable about a pivot 7130a. The jaw
assembly drive comprises a translatable actuator rod 7160a and
drive links 7140a which are pivotably coupled to the actuator rod
7160a about a pivot 7150a. The drive links 7140a are also pivotably
coupled to the jaws 7110a and 7120a such that the jaws 7110a and
7120a are rotated closed when the actuator rod 7160a is pulled
proximally and rotated open when the actuator rod 7160a is pushed
distally. The clutch system 6000a is similar to the clutch systems
6000 and 6000' in many respects, most of which will not be repeated
herein for the sake of brevity. The clutch system 6000a comprises a
first clutch assembly 6100a and a second clutch assembly 6200a
which are configured to selectively transmit the rotation of a
drive input 6030a to rotate the jaw assembly 7100a about a
longitudinal axis and articulate the jaw assembly 7100a about an
articulation joint 7300a, respectively, as described in greater
detail below.
[0316] The first clutch assembly 6100a comprises clutch plates
6110a and drive rings 6120a and work in a manner similar to the
clutch plates 6110' and drive rings 6120' discussed above. When the
clutch plates 6110a are actuated by an electromagnetic actuator
6140a, the rotation of the drive input 6030a is transferred to an
outer shaft housing 7200a. More specifically, the outer shaft
housing 7200a comprises a proximal outer housing 7210a and a distal
outer housing 7220a which is rotatably supported by the proximal
outer housing 7210a and is rotated relative to the proximal outer
housing 7210a by the drive input 6030a when the clutch plates 6110a
are in their actuated position. The rotation of the distal outer
housing 7220a rotates the jaw assembly 7100a about the longitudinal
axis owing to fact that the pivot 7130a of the jaw assembly 7100a
is mounted to the distal outer housing 7220a. As a result, the
outer shaft housing 7200a rotates the jaw assembly 7100a in a first
direction when the outer shaft housing 7200a is rotated in a first
direction by the drive input 6030a. Similarly, the outer shaft
housing 7200a rotates the jaw assembly 7100a in a second direction
when the outer shaft housing 7200a is rotated in a second direction
by the drive input 6030a. When the electromagnetic actuator 6140a
is de-energized, the drive rings 6120a expand and the clutch plates
6110a are moved into their unactuated positions, thereby decoupling
the end effector rotation drive from the drive input 6030a.
[0317] The second clutch assembly 6200a comprises clutch plates
6210a and drive rings 6220a and work in a manner similar to the
clutch plates 6110' and drive rings 6120' discussed above. When the
clutch plates 6210a are actuated by an electromagnetic actuator
6240a, the rotation of the drive input 6030a is transferred to an
articulation drive 6230a. The articulation drive 6230a is rotatably
supported within an outer shaft housing 7410a of an end effector
attachment portion 7400a and is rotatably supported by a shaft
frame 6050a extending through the outer shaft housing 7410a. The
articulation drive 6230a comprises a gear face defined thereon
which is operably intermeshed with a stationary gear face 7230a
defined on the proximal outer housing 7210a of the outer shaft
housing 7200a. As a result, the articulation drive 6230a
articulates the outer shaft housing 7200a and the jaw assembly
7100a in a first direction when the articulation drive 6230a is
rotated in a first direction by the drive input 6030a. Similarly,
the articulation drive 6230a articulates the outer shaft housing
7200a and the jaw assembly 7100a in a second direction when the
articulation drive 6230a is rotated in a second direction by the
drive input 6030a. When the electromagnetic actuator 6240a is
de-energized, the drive rings 6220a expand and the clutch plates
6210a are moved into their unactuated positions, thereby decoupling
the end effector articulation drive from the drive input 6030a.
[0318] Further to the above, the shaft assembly 4000 is illustrated
in FIGS. 45-49. The shaft assembly 4000 is similar to the shaft
assemblies 2000, 2000', 2000''', and 2000'''' in many respects,
most of which will not be repeated herein for the sake of brevity.
The shaft assembly 4000 comprises a proximal portion 4100, an
elongate shaft 4200, a distal attachment portion 2400, and an
articulate joint 2300 which rotatably connects the distal
attachment portion 2040 to the elongate shaft 4200. The proximal
portion 4100, similar to the proximal portion 2100, is operably
attachable to the drive module 1100 of the handle 1000. The
proximal portion 4100 comprises a housing 4110 including an
attachment interface 4130 configured to mount the shaft assembly
4000 to the attachment interface 1130 of the handle 1000. The shaft
assembly 4000 further comprises a frame 4500 including a shaft 4510
configured to be coupled to the shaft 1510 of the handle frame 1500
when the shaft assembly 4000 is attached to the handle 1000. The
shaft assembly 4000 also comprises a drive system 4700 including a
rotatable drive shaft 4710 configured to be operably coupled to the
drive shaft 1710 of the handle drive system 1700 when the shaft
assembly 4000 is attached to the handle 1000. The distal attachment
portion 2400 is configured to receive an end effector, such as end
effector 8000, for example. The end effector 8000 is similar to the
end effector 7000 in many respects, most of which will not be
repeated herein for the sake of brevity. That said, the end
effector 8000 comprises a jaw assembly 8100 configured to, among
other things, grasp tissue.
[0319] As discussed above, referring primarily to FIGS. 47-49, the
frame 4500 of the shaft assembly 4000 comprises a frame shaft 4510.
The frame shaft 4510 comprises a notch, or cut-out, 4530 defined
therein. As discussed in greater detail below, the cut-out 4530 is
configured to provide clearance for a jaw closure actuation system
4600. The frame 4500 further comprises a distal portion 4550 and a
bridge 4540 connecting the distal portion 4550 to the frame shaft
4510. The frame 4500 further comprises a longitudinal portion 4560
extending through the elongate shaft 4200 to the distal attachment
portion 2400. Similar to the above, the frame shaft 4510 comprises
one or more electrical traces defined thereon and/or therein. The
electrical traces extend through the longitudinal portion 4560, the
distal portion 4550, the bridge 4540, and/or any suitable portion
of the frame shaft 4510 to the electrical contacts 2520. Referring
primarily to FIG. 48, the distal portion 4550 and longitudinal
portion 4560 comprise a longitudinal aperture defined therein which
is configured to receive a rod 4660 of the jaw closure actuation
system 4600, as described in greater detail below.
[0320] As also discussed above, referring primarily to FIGS. 48 and
49, the drive system 4700 of the shaft assembly 4000 comprises a
drive shaft 4710. The drive shaft 4710 is rotatably supported
within the proximal shaft housing 4110 by the frame shaft 4510 and
is rotatable about a longitudinal axis extending through the frame
shaft 4510. The drive system 4700 further comprises a transfer
shaft 4750 and an output shaft 4780. The transfer shaft 4750 is
also rotatably supported within the proximal shaft housing 4110 and
is rotatable about a longitudinal axis extending parallel to, or at
least substantially parallel to, the frame shaft 4510 and the
longitudinal axis defined therethrough. The transfer shaft 4750
comprises a proximal spur gear 4740 fixedly mounted thereto such
that the proximal spur gear 4740 rotates with the transfer shaft
4750. The proximal spur gear 4740 is operably intermeshed with an
annular gear face 4730 defined around the outer circumference of
the drive shaft 4710 such that the rotation of the drive shaft 4710
is transferred to the transfer shaft 4750. The transfer shaft 4750
further comprises a distal spur gear 4760 fixedly mounted thereto
such that the distal spur gear 4760 rotates with the transfer shaft
4750. The distal spur gear 4760 is operably intermeshed with an
annular gear 4770 defined around the outer circumference of the
output shaft 4780 such that the rotation of the transfer shaft 4750
is transferred to the output shaft 4780. Similar to the above, the
output shaft 4780 is rotatably supported within the proximal shaft
housing 4110 by the distal portion 4550 of the shaft frame 4500
such that the output shaft 4780 rotates about the longitudinal
shaft axis. Notably, the output shaft 4780 is not directly coupled
to the input shaft 4710; rather, the output shaft 4780 is operably
coupled to the input shaft 4710 by the transfer shaft 4750. Such an
arrangement provides room for the manually-actuated jaw closure
actuation system 4600 discussed below.
[0321] Further to the above, referring primarily to FIGS. 47 and
48, the jaw closure actuation system 4600 comprises an actuation,
or scissors, trigger 4610 rotatably coupled to the proximal shaft
housing 4110 about a pivot 4620. The actuation trigger 4610
comprises an elongate portion 4612, a proximal end 4614, and a grip
ring aperture 4616 defined in the proximal end 4614 which is
configured to be gripped by the clinician. The shaft assembly 4000
further comprises a stationary grip 4160 extending from the
proximal housing 4110. The stationary grip 4160 comprises an
elongate portion 4162, a proximal end 4164, and a grip ring
aperture 4166 defined in the proximal end 4164 which is configured
to be gripped by the clinician. In use, as described in greater
detail below, the actuation trigger 4610 is rotatable between an
unactuated position and an actuated position (FIG. 48), i.e.,
toward the stationary grip 4160, to close the jaw assembly 8100 of
the end effector 8000.
[0322] Referring primarily to FIG. 48, the jaw closure actuation
system 4600 further comprises a drive link 4640 rotatably coupled
to the proximal shaft housing 4110 about a pivot 4650 and, in
addition, an actuation rod 4660 operably coupled to the drive link
4640. The actuation rod 4660 extends through an aperture defined in
the longitudinal frame portion 4560 and is translatable along the
longitudinal axis of the shaft frame 4500. The actuation rod 4660
comprises a distal end operably coupled to the jaw assembly 8100
and a proximal end 4665 positioned in a drive slot 4645 defined in
the drive link 4640 such that the actuation rod 4660 is translated
longitudinally when the drive link 4640 is rotated about the pivot
4650. Notably, the proximal end 4665 is rotatably supported within
the drive slot 4645 such that the actuation rod 4660 can rotate
with the end effector 8000.
[0323] Further to the above, the actuation trigger 4610 further
comprises a drive arm 4615 configured to engage and rotate the
drive link 4640 proximally, and translate the actuation rod 4660
proximally, when the actuation trigger 4610 is actuated, i.e.,
moved closer to the proximal shaft housing 4110. In such instances,
the proximal rotation of the drive link 4640 resiliently compresses
a biasing member, such as a coil spring 4670, for example,
positioned intermediate the drive link 4640 and the frame shaft
4510. When the actuation trigger 4610 is released, the compressed
coil spring 4670 re-expands and pushes the drive link 4640 and the
actuation rod 4660 distally to open the jaw assembly 8100 of the
end effector 8000. Moreover, the distal rotation of the drive link
4640 drives, and automatically rotates, the actuation trigger 4610
back into its unactuated position. That being said, the clinician
could manually return the actuation trigger 4610 back into its
unactuated position. In such instances, the actuation trigger 4610
could be opened slowly. In either event, the shaft assembly 4000
further comprises a lock configured to releasably hold the
actuation trigger 4610 in its actuated position such that the
clinician can use their hand to perform another task without the
jaw assembly 8100 opening unintentionally.
[0324] In various alternative embodiments, further to the above,
the actuation rod 4660 can be pushed distally to close the jaw
assembly 8100. In at least one such instance, the actuation rod
4660 is mounted directly to the actuation trigger 4610 such that,
when the actuation trigger 4610 is actuated, the actuation trigger
4610 drives the actuation rod 4660 distally. Similar to the above,
the actuation trigger 4610 can compress a spring when the actuation
trigger 4610 is closed such that, when the actuation trigger 4610
is released, the actuation rod 4660 is pushed proximally.
[0325] Further to the above, the shaft assembly 4000 has three
functions--opening/closing the jaw assembly of an end effector,
rotating the end effector about a longitudinal axis, and
articulating the end effector about an articulation axis. The end
effector rotation and articulation functions of the shaft assembly
4000 are driven by the motor assembly 1600 and the control system
1800 of the drive module 1100 while the jaw actuation function is
manually-driven by the jaw closure actuation system 4600. The jaw
closure actuation system 4600 could be a motor-driven system but,
instead, the jaw closure actuation system 4600 has been kept a
manually-driven system such that the clinician can have a better
feel for the tissue being clamped within the end effector. While
motorizing the end effector rotation and actuation systems provides
certain advantages for controlling the position of the end
effector, motorizing the jaw closure actuation system 4600 may
cause the clinician to lose a tactile sense of the force being
applied to the tissue and may not be able to assess whether the
force is insufficient or excessive. Thus, the jaw closure actuation
system 4600 is manually-driven even though the end effector
rotation and articulation systems are motor-driven.
[0326] FIG. 50 is a logic diagram of the control system 1800 of the
surgical system depicted in FIG. 1 in accordance with at least one
embodiment. The control system 1800 comprises a control circuit.
The control circuit includes a microcontroller 1840 comprising a
processor 1820 and a memory 1830. One or more sensors, such as
sensors 1880, 1890, 6180', 6280', 6380', 7190'', and/or 6290''',
for example, provide real time feedback to the processor 1820. The
control system 1800 further comprises a motor driver 1850
configured to control the electric motor 1610 and a tracking system
1860 configured to determine the position of one or more
longitudinally movable components in the surgical instrument, such
as the clutches 6110, 6120, and 6130 and/or the
longitudinally-movable drive nut 7150 of the jaw assembly drive,
for example. The tracking system 1860 is also configured to
determine the position of one or more rotational components in the
surgical instrument, such as the drive shaft 2530, the outer shaft
6230, and/or the articulation drive 6330, for example. The tracking
system 1860 provides position information to the processor 1820,
which can be programmed or configured to, among other things,
determine the position of the clutches 6110, 6120, and 6130 and the
drive nut 7150 as well as the orientation of the jaws 7110 and
7120. The motor driver 1850 may be an A3941 available from Allegro
Microsystems, Inc., for example; however, other motor drivers may
be readily substituted for use in the tracking system 1860. A
detailed description of an absolute positioning system is described
in U.S. Patent Application Publication No. 2017/0296213, entitled
SYSTEMS AND METHODS FOR CONTROLLING A SURGICAL STAPLING AND CUTTING
INSTRUMENT, the entire disclosure of which is hereby incorporated
herein by reference.
[0327] The microcontroller 1840 may be any single core or multicore
processor such as those known under the trade name ARM Cortex by
Texas Instruments, for example. In at least one instance, the
microcontroller 1840 is a LM4F230H5QR ARM Cortex-M4F Processor
Core, available from Texas Instruments, for example, 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 and/or frequency modulation (FM) modules,
one or more quadrature encoder inputs (QEI) analog, one or more
12-bit Analog-to-Digital Converters (ADC) with 12 analog input
channels, for example, details of which are available from the
product datasheet.
[0328] In various instances, the microcontroller 1840 comprises a
safety controller comprising two controller-based families such as
TMS570 and RM4x known under the trade name Hercules ARM Cortex R4,
also by Texas Instruments. The safety controller 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.
[0329] The microcontroller 1840 is programmed to perform various
functions such as precisely controlling the speed and/or position
of the drive nut 7150 of the jaw closure assembly, for example. The
microcontroller 1840 is also programmed to precisely control the
rotational speed and position of the end effector 7000 and the
articulation speed and position of the end effector 7000. In
various instances, the microcontroller 1840 computes a response in
the software of the microcontroller 1840. The computed response is
compared to a measured response of the actual system to obtain an
"observed" response, which is used for actual feedback decisions.
The observed response is a favorable, tuned, value that balances
the smooth, continuous nature of the simulated response with the
measured response, which can detect outside influences on the
system.
[0330] The motor 1610 is controlled by the motor driver 1850. In
various forms, the motor 1610 is a DC brushed driving motor having
a maximum rotational speed of approximately 25,000 RPM, for
example. In other arrangements, the motor 1610 includes a brushless
motor, a cordless motor, a synchronous motor, a stepper motor, or
any other suitable electric motor. The motor driver 1850 may
comprise an H-bridge driver comprising field-effect transistors
(FETs), for example. The motor driver 1850 may be an A3941
available from Allegro Microsystems, Inc., for example. The A3941
driver 1850 is a full-bridge controller for use with external
N-channel power metal oxide semiconductor field effect transistors
(MOSFETs) specifically designed for inductive loads, such as brush
DC motors. In various instances, the driver 1850 comprises a unique
charge pump regulator provides full (>10 V) gate drive for
battery voltages down to 7 V and allows the A3941 to operate with a
reduced gate drive, down to 5.5 V. A bootstrap capacitor may be
employed to provide the above-battery supply voltage required for
N-channel MOSFETs. An internal charge pump for the high-side drive
allows DC (100% duty cycle) operation. The full bridge can be
driven in fast or slow decay modes using diode or synchronous
rectification. In the slow decay mode, current recirculation can be
through the high-side or the lowside FETs. The power FETs are
protected from shoot-through by resistor adjustable dead time.
Integrated diagnostics provide indication of undervoltage,
overtemperature, and power bridge faults, and can be configured to
protect the power MOSFETs under most short circuit conditions.
Other motor drivers may be readily substituted.
[0331] The tracking system 1860 comprises a controlled motor drive
circuit arrangement comprising one or more position sensors, such
as sensors 1880, 1890, 6180', 6280', 6380', 7190'', and/or 6290''',
for example. The position sensors for an absolute positioning
system provide a unique position signal corresponding to the
location of a displacement member. As used herein, the term
displacement member is used generically to refer to any movable
member of the surgical system. In various instances, the
displacement member may be coupled to any position sensor suitable
for measuring linear displacement. Linear displacement sensors may
include contact or non-contact displacement sensors. Linear
displacement sensors may comprise linear variable differential
transformers (LVDT), differential variable reluctance transducers
(DVRT), a slide potentiometer, a magnetic sensing system comprising
a movable magnet and a series of linearly arranged Hall Effect
sensors, a magnetic sensing system comprising a fixed magnet and a
series of movable linearly arranged Hall Effect sensors, an optical
sensing system comprising a movable light source and a series of
linearly arranged photo diodes or photo detectors, or an optical
sensing system comprising a fixed light source and a series of
movable linearly arranged photo diodes or photo detectors, or any
combination thereof.
[0332] The position sensors 1880, 1890, 6180', 6280', 6380',
7190'', and/or 6290''', for example, may comprise any number of
magnetic sensing elements, such as, for example, magnetic sensors
classified according to whether they measure the total magnetic
field or the vector components of the magnetic field. The
techniques used to produce both types of magnetic sensors encompass
many aspects of physics and electronics. The technologies used for
magnetic field sensing include search coil, fluxgate, optically
pumped, nuclear precession, SQUID, Hall-Effect, anisotropic
magnetoresistance, giant magnetoresistance, magnetic tunnel
junctions, giant magnetoimpedance, magnetostrictive/piezoelectric
composites, magnetodiode, magnetotransistor, fiber optic,
magnetooptic, and microelectromechanical systems-based magnetic
sensors, among others.
[0333] In various instances, one or more of the position sensors of
the tracking system 1860 comprise a magnetic rotary absolute
positioning system. Such position sensors may be implemented as an
AS5055EQFT single-chip magnetic rotary position sensor available
from Austria Microsystems, AG and can be interfaced with the
controller 1840 to provide an absolute positioning system. In
certain instances, a position sensor comprises a low-voltage and
low-power component and includes four Hall-Effect elements in an
area of the position sensor that is located adjacent a magnet. A
high resolution ADC and a smart power management controller are
also provided on the chip. A CORDIC processor (for Coordinate
Rotation Digital Computer), also known as the digit-by-digit method
and Volder's algorithm, is provided to implement a simple and
efficient algorithm to calculate hyperbolic and trigonometric
functions that require only addition, subtraction, bitshift, and
table lookup operations. The angle position, alarm bits, and
magnetic field information are transmitted over a standard serial
communication interface such as an SPI interface to the controller
1840. The position sensors can provide 12 or 14 bits of resolution,
for example. The position sensors can be an AS5055 chip provided in
a small QFN 16-pin 4.times.4.times.0.85 mm package, for
example.
[0334] The tracking system 1860 may comprise and/or be programmed
to implement a feedback controller, such as a PID, state feedback,
and adaptive controller. A power source converts the signal from
the feedback controller into a physical input to the system, in
this case voltage. Other examples include pulse width modulation
(PWM) and/or frequency modulation (FM) of the voltage, current, and
force. Other sensor(s) may be provided to measure physical
parameters of the physical system in addition to position. In
various instances, the other sensor(s) can include sensor
arrangements such as those described in U.S. Pat. No. 9,345,481,
entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which is
hereby incorporated herein by reference in its entirety; U.S.
Patent Application Publication No. 2014/0263552, entitled STAPLE
CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which is hereby
incorporated herein by reference in its entirety; and U.S. patent
application Ser. No. 15/628,175, entitled TECHNIQUES FOR ADAPTIVE
CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLING AND CUTTING
INSTRUMENT, which is hereby incorporated herein by reference in its
entirety. In a digital signal processing system, absolute
positioning system is coupled to a digital data acquisition system
where the output of the absolute positioning system will have
finite resolution and sampling frequency. The absolute positioning
system may comprise a compare and combine circuit to combine a
computed response with a measured response using algorithms such as
weighted average and theoretical control loop that drives the
computed response towards the measured response. The computed
response of the physical system takes into account properties like
mass, inertial, viscous friction, inductance resistance, etc., to
predict what the states and outputs of the physical system will be
by knowing the input.
[0335] The absolute positioning system provides an absolute
position of the displacement member upon power up of the instrument
without retracting or advancing the displacement member to a reset
(zero or home) position as may be required with conventional rotary
encoders that merely count the number of steps forwards or
backwards that the motor 1610 has taken to infer the position of a
device actuator, drive bar, knife, and the like.
[0336] A sensor 1880 comprising a strain gauge or a micro-strain
gauge, for example, is configured to measure one or more parameters
of the end effector, such as, for example, the strain experienced
by the jaws 7110 and 7120 during a clamping operation. The measured
strain is converted to a digital signal and provided to the
processor 1820. In addition to or in lieu of the sensor 1880, a
sensor 1890 comprising a load sensor, for example, can measure the
closure force applied by the closure drive system to the jaws 7110
and 7120. In various instances, a current sensor 1870 can be
employed to measure the current drawn by the motor 1610. The force
required to clamp the jaw assembly 7100 can correspond to the
current drawn by the motor 1610, for example. The measured force is
converted to a digital signal and provided to the processor 1820. A
magnetic field sensor can be employed to measure the thickness of
the captured tissue. The measurement of the magnetic field sensor
can also be converted to a digital signal and provided to the
processor 1820.
[0337] The measurements of the tissue compression, the tissue
thickness, and/or the force required to close the end effector on
the tissue as measured by the sensors can be used by the controller
1840 to characterize the position and/or speed of the movable
member being tracked. In at least one instance, a memory 1830 may
store a technique, an equation, and/or a look-up table which can be
employed by the controller 1840 in the assessment. In various
instances, the controller 1840 can provide the user of the surgical
instrument with a choice as to the manner in which the surgical
instrument should be operated. To this end, the display 1440 can
display a variety of operating conditions of the instrument and can
include touch screen functionality for data input. Moreover,
information displayed on the display 1440 may be overlaid with
images acquired via the imaging modules of one or more endoscopes
and/or one or more additional surgical instruments used during the
surgical procedure.
[0338] As discussed above, the drive module 1100 of the handle 1000
and/or the shaft assemblies 2000, 3000, 4000, and/or 5000, for
example, attachable thereto comprise control systems. Each of the
control systems can comprise a circuit board having one or more
processors and/or memory devices. Among other things, the control
systems are configured to store sensor data, for example. They are
also configured to store data which identifies the shaft assembly
to the handle 1000. Moreover, they are also configured to store
data including whether or not the shaft assembly has been
previously used and/or how many times the shaft assembly has been
used. This information can be obtained by the handle 1000 to assess
whether or not the shaft assembly is suitable for use and/or has
been used less than a predetermined number of times, for
example.
[0339] A drive module 1100' in accordance with at least one
alternative embodiment is illustrated in FIGS. 51-53. The drive
module 1100' is similar to the drive module 1100 in many respects,
most of which will not be discussed herein for the sake of brevity.
The drive module 1100' comprises an actuator 1420' configured to
control the rotation and articulation of the end effector 7000.
Similar to the actuator 1420, discussed above, the actuator 1420'
is rotatable about a longitudinal axis LA that extends through a
shaft assembly attached to the drive module 1100. For instance, the
longitudinal axis LA extends through the center, or substantially
the center, of the elongate shaft 2200 of the shaft assembly 3000
(FIG. 1) when the shaft assembly 3000 is assembled to the drive
module 1100'. The longitudinal axis LA also extends through the
center, or substantially the center, of the end effector 7000 when
the end effector 7000 is attached to the shaft assembly 3000, for
example.
[0340] The actuator 1420' is rotatable within a channel 1190'
defined in the housing 1110 in a first direction to rotate the end
effector 7000 in the first direction and, similarly, in a second,
or opposite, direction to rotate the end effector 7000 in the
second direction. Similar to the drive module 1100, the drive
module 1100' comprises a sensor system in communication with the
control system 1800 configured to detect the rotation of the
actuator 1420' about the longitudinal axis LA. In at least one
instance, the sensor system comprises a first sensor 1422'
configured to detect the rotation of the actuator 1420' about the
longitudinal axis LA in the first direction (FIG. 52A) and a second
sensor 1424' configured to detect the rotation of the actuator
1420' about the longitudinal axis LA in the second direction (FIG.
52B). The first and second sensors 1422' and 1424' comprise Hall
Effect sensors, for example, but could comprise any suitable type
of sensor. In at least one such instance, further to the above, the
actuator 1420' comprises a center magnetic element 1426' positioned
in the top of the actuator 1420' which is detectable by the first
and second sensors 1422' and 1424' to determine the rotation of the
actuator 1420'. The center magnetic element 1426' can comprise a
permanent magnet and/or can be comprised of iron and/or nickel, for
example.
[0341] Further to the above, the control system 1800 is configured
to control the motor assembly 1600 and the clutch system 6000 to
rotate the end effector 7000 about the longitudinal axis LA in the
first direction when the actuator 1420' is rotated about the
longitudinal axis LA in the first direction. Similarly, the control
system 1800 is configured to control the motor assembly 1600 and
the clutch system 6000 to rotate the end effector 7000 about the
longitudinal axis LA in the second direction when the actuator
1420' is rotated about the longitudinal axis LA in the second
direction. By associating the rotation of the end effector 7000
about the longitudinal axis LA with the rotation of the actuator
1420' about the longitudinal axis LA, the clinician is provided
with a system that is very intuitive to use.
[0342] As discussed above, the end effector 7000 is configured to
rotate about a longitudinal axis within a socket defined in the
distal attachment portion 2400 of the shaft assembly 2000.
Depending on the amount of rotation desired, the end effector 7000
can be rotated less than 360 degrees or more than 360 degrees in
either direction. In various instances, the end effector 7000 can
be rotated through several rotations in either direction. In
alternative embodiments, the rotation of the end effector 7000
about the longitudinal axis can be limited. In at least one
embodiment, the shaft assembly 2000 comprises one or more stops
which limit the rotation of the end effector 7000 to less than one
rotation. In certain embodiments, the control system 1800 monitors
the rotation of the drive shaft 1710, such as by an encoder and/or
an absolute positioning sensor system, for example, and limits the
rotation of the end effector 7000 by stopping or pausing the motor
1610 when the end effector 7000 has reached the end of its
permitted range. In at least one instance, the control system 1800
can disengage the second clutch 6210 from the drive shaft 2730 to
stop or pause the rotation of the end effector 7000 when the end
effector 7000 has reached the end of its permitted range.
[0343] Further to the above, the drive module 1100' and/or a shaft
module attached to the drive module 1100' can provide feedback to
the clinician that the end effector 7000 has reached the end of its
rotation. The drive module 1100' and/or the shaft module attached
thereto can comprise an indicator light 1427', such as a red LED,
for example, on a first side of the module housing 1110' which is
illuminated by the control system 1800 when the end effector 7000
has reached the end of its permitted rotation in the first
direction, as illustrated in FIG. 52A. In at least one instance,
the drive module 1100' and/or the shaft module attached thereto can
comprise an indicator light 1429', such as a red LED, for example,
on a second side of the module housing 1110' which is illuminated
by the control system 1800 when the end effector 7000 has reached
the end of its permitted rotation in the second direction, as
illustrated in FIG. 52B. In various instances, further to the
above, the illumination of either the first light 1427' or the
second light 1429' can indicate to the clinician that the motor
1610 has been paused and that the end effector 7000 is no longer
rotating. In at least one instance, the first light 1427' and/or
the second light 1429' can blink when the motor 1610 is paused.
[0344] In addition to or in lieu of the above, the drive module
1100' and/or the shaft assembly attached thereto can comprise an
annular series, or array, of indicator lights 1428' extending
around the perimeter thereof which is in communication with the
control system 1800 and can indicate the rotational orientation of
the end effector 7000. In at least one instance, the control system
1800 is configured to illuminate the particular indicator light
which corresponds, or at least substantially corresponds, with the
position in which the top of the end effector 7000 is oriented. In
at least one instance, the center of the first jaw 7110 can be
deemed the top of the end effector 7000, for example. In such
instances, the illuminated light indicates the top-dead-center
position of the end effector 7000. In other instances, the control
system 1800 can illuminate the particular indicator light which
corresponds, or at least substantially corresponds, with the
position in which the bottom, or bottom-dead-center, of the end
effector 7000 is oriented. In at least one instance, the center of
the second jaw 7210 can be deemed the bottom of the end effector
7000, for example. As a result of the above, the illuminated
indicator light can follow the rotation of the end effector 7000
around the array of indicator lights 1428'.
[0345] Further to the above, the actuator 1420' is also rotatable,
or tiltable, about a transverse axis TA within the housing channel
1190'. The sensor system of the drive module 1100' is further
configured to detect the rotation of the actuator 1420' about the
transverse axis TA in a first tilt direction and a second tilt
direction. In at least one instance, the sensor system comprises a
first tilt sensor 1423' configured to detect the rotation of the
actuator 1420' about the longitudinal axis TA in the first tilt
direction (FIG. 53A) and a second tilt sensor 1425' configured to
detect the rotation of the actuator 1420' in the second tilt
direction (FIG. 53B). The first and second tilt sensors 1423' and
1425' comprise Hall Effect sensors, for example, but could comprise
any suitable type of sensor. The actuator 1420' further comprises a
first lateral magnetic element adjacent the first tilt sensor
1423', the motion of which is detectable by the first tilt sensor
1423'. The actuator 1420' also comprises a second lateral magnetic
element adjacent the second tilt sensor 1425', the motion of which
is detectable by the second tilt sensor 1425'. The first and second
lateral magnetic elements can comprise a permanent magnet and/or
can be comprised of iron and/or nickel, for example. As illustrated
in FIGS. 53A and 53B, the lateral sides of the actuator 1420' are
movable proximally and distally about the transverse axis TA and,
as a result, the first and second lateral magnetic elements are
also movable proximally and distally relative to the first and
second tilt sensors. The reader should appreciate that, while the
first and second lateral magnetic elements actually travel along
arcuate paths about the transverse axis TA, the distances in which
the first and second lateral magnetic elements move is small and,
as a result, the arcuate motion of the first and second lateral
magnetic elements approximates translation in the proximal and
distal directions.
[0346] In various embodiments, further to the above, the entire
actuator 1420' comprises a magnetic ring of material which is
detectable by the tilt sensors 1423' and 1425' of the drive module
1100'. In such embodiments, the rotation of the actuator 1420'
about the longitudinal axis LA would not create a compound motion
relative to the tilt sensors when the actuator 1420' is tilted. The
magnetic ring of material can comprise a permanent magnet and/or
can be comprised of iron and/or nickel, for example.
[0347] In any event, when the sensor system detects that the
actuator 1420' has been tilted in the first direction, as
illustrated in FIG. 53A, the control system 1800 operates the motor
assembly 1600 and the clutch system 6000 to articulate the end
effector 7000 about the articulation joint 2300 in the first
direction. Similarly, the control system 1800 operates the motor
assembly 1600 and the clutch system 6000 to articulate the end
effector 7000 about the articulation joint 2300 in the second
direction when the sensor system detects that the actuator 1420'
has been tilted in the second direction, as illustrated in FIG.
53B. By associating the rotation of the end effector 7000 about the
articulation joint 2300 with the rotation of the actuator 1420'
about the transverse axis TA, the clinician is provided with a
system that is very intuitive to use.
[0348] Further to the above, the actuator 1420' comprises a biasing
system configured to center the actuator 1420' in its unrotated and
untilted position. In various instances, the biasing system
comprises first and second rotation springs configured to center
the actuator 1420' in its unrotated position and first and second
tilt springs configured to center the actuator 1420' in its
untilted position. These springs can comprise torsion springs
and/or linear displacement springs, for example.
[0349] As discussed above, the end effector 7000 rotates relative
to the distal attachment portion 2400 of the shaft assembly 3000.
Such an arrangement allows the end effector 7000 to be rotated
without having to rotate the shaft assembly 3000, although
embodiments are possible in which an end effector and shaft
assembly rotate together. That said, by rotating the end effector
7000 relative to the shaft assembly 3000, all of the rotation of
the surgical system occurs distally relative to the articulation
joint 2300. Such an arrangement prevents a large sweep of the end
effector 7000 when the end effector 7000 is articulated and then
rotated. Moreover, the articulation joint 2300 does not rotate with
the end effector 7000 and, as a result, the articulation axis of
the articulation joint 2300 is unaffected by the rotation of the
end effector 7000. In order to mimic this arrangement, the
transverse axis TA does not rotate with the actuator 1420'; rather,
the transverse axis TA remains stationary with respect to the drive
module 1100'. That said, in alternative embodiments, the transverse
axis TA can rotate, or track the end effector 7000, when the
articulation joint rotates with the end effector. Such an
arrangement can maintain an intuitive relationship between the
motion of the actuator 1420' and the motion of the end effector
7000.
[0350] Further to the above, the transverse axis TA is orthogonal,
or at least substantially orthogonal, to the longitudinal axis LA.
Similarly, the articulation axis of the articulation joint 2300 is
orthogonal, or at least substantially orthogonal, to the
longitudinal axis LA. As a result, the transverse axis TA is
parallel to, or at least substantially parallel to, the
articulation axis.
[0351] In various alternative embodiments, the tiltable actuator
1420' is only used to control the articulation of the end effector
7000 and is not rotatable about the longitudinal axis LA. Rather,
in such embodiments, the actuator 1420' is only rotatable about the
transverse axis TA. In at least one instance, the housing of the
drive module 1100' comprises two posts 1421' (FIG. 51) about which
the actuator 1120' is rotatably mounted which defines the
transverse axis TA. The posts 1421' are aligned along a common
axis. The above being said, the posts 1421', or any suitable
structure, can be used in embodiments in which the actuator 1420'
is both rotatable and tiltable to control the rotation and
articulation of the end effector 7000. In at least one such
instance, the actuator 1420' comprises an annular groove defined
therein in which the posts 1421' are positioned.
[0352] In various instances, the drive module 1100 and/or the shaft
assembly attached thereto can comprise a series, or array, of
indicator lights 1438' which is in communication with the control
system 1800 and can indicate the articulation orientation of the
end effector 7000. In at least one instance, the control system
1800 is configured to illuminate the particular indicator light
which corresponds, or at least substantially corresponds, with the
position in which the end effector 7000 is articulated. As a result
of the above, the illuminated indicator light can follow the
articulation of the end effector 7000. Such an array of indicator
lights can assist a clinician in straightening the end effector
7000 before attempting to remove the end effector 7000 from a
patient through a trocar. In various instances, an unstraightened
end effector may not pass through a trocar and prevent the
removable of the end effector from the patient.
[0353] A drive module 1100'' in accordance with at least one
alternative embodiment is illustrated in FIGS. 54-57. The drive
module 1100'' is similar to the drive modules 1100 and 1100' in
many respects, most of which will not be discussed herein for the
sake of brevity. The drive module 1100'' comprises a feedback
system configured to inform the clinician using the surgical
instrument system that the drive shaft and/or any other rotatable
component of the surgical instrument system is rotating. The
feedback system can use visual feedback, audio feedback, and/or
tactile feedback, for example. Referring primarily to FIG. 55, the
drive module 1100'' comprises a tactile feedback system which is
operably engageable with the drive shaft 1710'' of the drive module
1100''. The tactile feedback system comprises a slideable clutch
1730'', a rotatable drive ring 1750'', and an eccentric, or offset,
mass 1770'' mounted to the drive ring 1750''. The clutch 1730'' is
slideable between an unactuated position (FIG. 56) and an actuated
position (FIG. 57) along the drive shaft 1710''. The drive shaft
1710'' comprises one or more slots 1740'' defined therein which are
configured to constrain the movement of the slideable clutch 1730''
relative to the drive shaft 1710'' such that the clutch 1730''
translates longitudinally relative to the drive shaft 1710'' but
also rotates with the drive shaft 1710''. The frame shaft 1510'' of
the handle frame 1500'' comprises an electromagnet 1530'' embedded
therein which is configured to emit a first electromagnetic field
to slide the clutch 1730'' toward its actuated position, as
illustrated in FIG. 57, and a second, or opposite, electromagnetic
field to slide the clutch 1730'' toward its unactuated position, as
illustrated in FIG. 56. The clutch 1730'' is comprised of a
permanent magnet and/or a magnetic material such as iron and/or
nickel, for example. The electromagnet 1530'' is controlled by the
control system 1800 to apply a first voltage polarity to a circuit
including the electromagnet 1530'' to create the first
electromagnetic field and a second, or opposite, voltage polarity
to the circuit to create the second electromagnetic field.
[0354] When the clutch 1730'' is in its unactuated position, as
illustrated in FIG. 56, the clutch 1730'' is not operably engaged
with the drive ring 1750''. In such instances, the clutch 1730''
rotates with the drive shaft 1710'', but rotates relative to the
drive ring 1750''. Stated another way, the drive ring 1750'' is
stationary when the clutch 1730'' is in its unactuated position.
When the clutch 1730'' is in its actuated position, as illustrated
in FIG. 57, the clutch 1730'' is operably engaged with an angled
face 1760'' of the drive ring 1750'' such that the rotation of the
drive shaft 1710'' is transmitted to the drive ring 1750'' via the
clutch 1730'' when the drive shaft 1710'' is rotated. The
eccentric, or offset, mass 1770'' is mounted to the drive ring
1750'' such that the eccentric mass 1770'' rotates with the drive
ring 1750''. In at least one instance, the eccentric mass 1770'' is
integrally-formed with the drive ring 1750''. When the drive ring
1750'' and eccentric mass 1770'' rotate with the drive shaft
1710'', the eccentric mass 1770'' creates a vibration that can be
felt by the clinician through the drive module 1100'' and/or the
power modules assembled thereto. This vibration confirms to the
clinician that the drive shaft 1710'' is rotating. In at least one
instance, the control system 1800 energizes the electromagnet
1530'' when one of the clutches of the clutch system 6000 is
energized. In such instances, the vibration can confirm to the
clinician that the drive shaft 1710'' is rotating and that one of
the clutches in the clutch system 6000 is engaged with the drive
shaft 1710''. In at least one instance, the clutch 1730'' can be
actuated when the jaw assembly 7100, for example, has reached or is
reaching its closed position such that the clinician knows that the
tissue has been clamped within the jaw assembly 7100 and that the
surgical instrument can be used to manipulate the tissue. The above
being said, the tactile feedback system, and/or any other feedback
system, of the drive module 1100'' can be used to provide tactile
feedback when appropriate.
[0355] Sterilization processes are part of customary surgical
preparation procedures. A variety of sterilization processes exist
for surgical instruments. Various methods include sterilization by
way of autoclave which utilizes high heat and pressure, and
sterilization utilizing steam, dry heat, and/or radiation, for
example. However, one of the most widely used methods of
sterilization is ethylene oxide processing. Ethylene oxide is an
alkylating chemical compound which inhibits and disrupts the DNA of
microorganisms in order to prevent reproduction of those organisms.
Ethylene oxide processing is a highly effective sterilization
process, but it does not come without cost. Some of the early steps
involved during ethylene oxide processing involve heating the
surgical instruments to a sustainable internal temperature and
humidifying the surgical instruments. Often times, the surgical
instruments undergo the heating and humidifying processes for
anywhere from twelve to seventy-two hours during a single
sterilization process. In addition to the heat and humidity, the
potency of ethylene oxide tends to affect the soft electronic
circuitry of powered surgical instruments. In the field of
endoscopy, certain components of the powered endoscopy surgical
instruments, such as display screens, for example, react poorly to
the sterilization process when ethylene oxide is used. Improperly
functioning display screens could result in difficulties and/or
delays during a surgical procedure. Thus, a need exists for a
surgical instrument system which incorporates a variety of
cost-efficient disposable and replaceable components in order to
avoid the damage caused by the sterilization process.
[0356] A surgical instrument system is illustrated in FIG. 58. The
surgical instrument system illustrated in FIG. 58 is similar to the
surgical instrument system depicted in FIG. 1 in many respects,
most of which will not be repeated herein out of the sake of
brevity. The surgical instrument system comprises a variety of
interchangeable shaft assemblies and power modules, as will be
discussed in greater detail below. The surgical instrument system
comprises a handle assembly 11000. The handle assembly 11000 is
usable with a variety of interchangeable shaft assemblies, such as
a shaft assembly 12000, a shaft assembly 13000, a shaft assembly
14000, a shaft assembly 15000, and/or other any other suitable
shaft assembly. The interchangeable shaft assemblies 12000, 13000,
14000, and 15000 are similar to the shaft assemblies 2000, 3000,
4000, and 5000 in many respects. Similar to the shaft assembly
2000, the shaft assembly 12000 comprises a proximal end portion
12100 and an elongate shaft 12200 extending from the proximal end
portion 12100. The shaft assembly 12000 also comprises an end
effector 12400 which is rotatably attached to the elongate shaft
12200 by an articulation joint 12300. The end effector 12400
comprises a first jaw 17000 and a second jaw 17100. Similar to the
shaft assembly 12000, the shaft assembly 13000 comprises a proximal
end portion 13100, and an elongate shaft 13200 extending from the
proximal end portion 13100. The shaft assembly 13000 is also
configured for use with the end effector 12400 which is rotatably
attached to the elongate shaft 13200 by an articulation joint
12300. Similar to the shaft assembly 12000, the shaft assembly
14000 comprises a proximal end portion 14100, and an elongate shaft
14200 extending from the proximal end portion 14100. The shaft
assembly 14000 is also configured for use with an end effector
12400' which is rotatably attached to the elongate shaft 14200 by
an articulation joint 12300. The end effector 12400' comprises a
first jaw 18000 and a second jaw 18100. The shaft assembly 15000
comprises similar components to those of the shaft assemblies
12000, 13000, and 14000, many of which will not be discussed in
detail for the sake of brevity.
[0357] Still referring to FIG. 58, the handle assembly 11000
comprises a drive module 11100. The drive module 11100 comprises a
distal mounting interface 11130 which allows for the selective and
separate engagement of any one of the shaft assemblies 12000,
13000, 14000, and 15000 with the drive module 11100. Each of the
shaft assemblies 12000, 13000, 14000, and 15000 comprises the same
or a substantially similar proximal mounting interface which is
configured to engage the distal mounting interface of the drive
module 11100. Still referring to FIG. 58, the shaft assembly 12000
comprises a proximal mounting interface 12130 which is configured
for attachment to the distal mounting interface 11130 of the drive
module 11100 by at least one latch 11140 of the drive module 11100.
Similarly, the shaft assembly 13000 comprises a proximal mounting
interface 13130 which is configured for attachment to the distal
mounting interface 11130 of the drive module 11100 by at least one
latch 11140 of the drive module 11100. Also, similarly, the shaft
assembly 14000 comprises a proximal mounting interface 14130 which
is configured for attachment to the distal mounting interface 11130
of the drive module 11100 by at least one latch 11140 of the drive
module 11100. Likewise, the shaft assembly 15000 comprises a
proximal mounting interface 15130 which is configured for
attachment to the distal mounting interface 11130 of the drive
module 11100. The drive module 11100 is configured to electrically
couple to each of the shaft assembles 12000, 13000, 14000, and
15000. The surgical instrument system comprises a motor positioned
in the handle assembly 11000, as will be discussed in greater
detail below. Each of the shaft assemblies 12000, 13000, 14000, and
15000 comprises a control circuit as will be discussed in greater
detail below. The control circuit is configured to interact with
the motor in order to control various functions of the surgical
instrument system. The surgical instrument system further comprises
a motor-control processor which is configured to communicate with
the control circuit in order to control the motor. Referring to
FIG. 76A, the processor is positioned in any suitable portion of
the surgical instrument apart from the drive module 11100. For
example, the processor is positioned in a shaft assembly of the
surgical instrument system. The handle assembly 11000 is configured
for use with at least one power module as will be discussed in
greater detail below.
[0358] Referring to FIGS. 58 and 59, the drive module 11100
comprises a housing 11110 which is capable of use with a variety of
power modules such as the power modules 11200 and 11300, for
example. In various instances, each power module 11200 and 11300
comprises one or more battery cells, as illustrated in FIG. 59,
which are configured to enable pistol, scissor, and/or pencil grip
configurations comprising different load requirements. In
particular, the housing 11110 comprises a first attachment portion
11120 and a second attachment portion 11120' which are configured
to engage either the power module 11200 or the power module 11300
at either the bottom of the handle assembly 11000 or the proximal
end of the handle assembly 11000 depending on which shaft assembly
is attached to the handle assembly 11000. For example, when the
shaft assembly 14000 is attached to the handle assembly 11000, a
power module is attached to the proximal end of the handle assembly
11000 in a first configuration as illustrated in FIG. 58. As
another example, when the shaft assembly 13000 is attached to the
handle assembly 11000, a power module is attached to the bottom of
the handle assembly 11000 in a second configuration. As illustrated
in FIGS. 58 and 59, the first configuration and the second
configuration are different from one another.
[0359] Still referring to FIG. 59, the drive module 11100 comprises
a rotation actuator 11420 which is similar to the rotation actuator
1420, which is described in greater detail above. The drive module
11100 further comprises release actuators 11150 which, when
depressed by a clinician, move the latches 11140 from their locked
positions into their unlocked positions. The drive module 11100
comprises a first release actuator 11150 slideably mounted in an
opening defined in the first side of the handle housing 11110 and a
second release actuator 11150 slideably mounted in an opening
defined in a second, or opposite, side of the handle housing
11110.
[0360] Referring to FIG. 59 and FIG. 60, the drive module 11100
comprises an articulation actuator 11430. The articulation actuator
11430 comprises a first push button 11432 and a second push button
11434. The first push button 11432 is part of a first articulation
control circuit and the second push button 11434 is part of a
second articulation circuit of an input system similar to the input
system 1400 discussed in greater detail above.
[0361] Referring again to FIG. 58, the surgical instrument system
comprises a power module 11200. The power module 11200 comprises a
housing 11210, a connector portion 11220, and at least one battery
(as illustrated in at least FIG. 59). The connector portion 11220
is configured to be engaged with the first connector portion 11120
in order to attach the power module 11200 to the bottom of the
handle assembly 11000. The power module 11200 comprises at least
one latch 11240 positioned at the top of the power module 11200
which is configured to secure the power module 11200 to the bottom
of the drive module 11100. More specifically, the latch 11240 is
configured to securely attach the housing 11210 of the power module
11200 to the housing 11110 of the drive module 11100 located within
the handle assembly 11000. The connector portion 11220 comprises a
plurality of electrical contacts which enable an electrical
connection between the power module 11200 and the drive module
11100. The power module 11200 comprises a release latch 11250 which
is configured to release the power module 11250 from the drive
module 11000.
[0362] Referring again to FIG. 58, the surgical instrument system
comprises a power module 11300. The power module 11300 comprises a
housing 11310, a connector portion 11320, and at least one battery.
The connector portion 11320 is configured to be engaged with the
second connector portion 11120' in order to attach the power module
11300 to the handle assembly 11000. The power module 11300
comprises at least one latch 11340 positioned at a distal end of
the power module 11300 which is configured to secure the power
module 11300 to the drive module 11100. More specifically, the
latch 11340 is configured to securely attach the housing 11310 of
the power module 11300 to the housing 11110 of the drive module
11100 located within the handle assembly 11000. The connector
portion 11320 comprises a plurality of electrical contacts which
enable an electrical connection between the power module 11300 and
the drive module 11100.
[0363] Still referring to FIG. 58, the power module 11200 and the
power module 11300 each comprise at least one display unit. The
power module 11200 comprises a display unit 11440 located on the
power module housing 11210. The power module 11300 comprises a
display unit 11440'. The display units 11440 and 11440' can
comprise any suitable display screen, for example, configured for
use with a powered surgical device. In various instances, the
display units 11440 and 11440' comprise an electrochromic display.
The electrochromic display comprises an array of electrodes created
from a metal oxide semi conductor. The electrodes are mounted on a
flexible film comprising attachments of electrochromic molecules.
As a charge is applied to the semiconducting electrodes, the
electrochromic molecules travel to the surface of the film to
receive the charge. As the electrochromic molecules are charged, a
change in color occurs in the molecules. Suitable versions of this
type of display screen are available from Ntera and Seiko, for
instance.
[0364] In certain instances, the display units 11440 and 11440'
comprise an electrophoretic display. The electrophoretic display
comprises titanium dioxide particles approximately one micrometer
in diameter which are dispersed in a hydrocarbon oil, for example.
A dark-colored dye is also added to the oil, along with surfactants
and charging agents that cause the particles to take on an electric
charge. The mixture of titanium dioxide particles and hydrocarbon
oil is placed between two parallel conductive plates separated by a
gap of 10 to 100 micrometers, for example. The parallel conductive
plates comprise opposite charges from one another. When a voltage
is applied across the two plates, the titanium dioxide particles
migrate electrophoretically to the plate that bears the opposite
charge from the charge of the particles. When the particles are
located at the front (viewing) side of the display, it appears
white, because light is scattered back to the viewer by the
high-index titanium dioxide particles. When the particles are
located at the rear side of the display, it appears dark, because
the incident light is absorbed by the colored dye. If the rear
electrode is divided into a number of small picture elements
(pixels), then an image can be formed by applying the appropriate
voltage to each region of the display to create a pattern of
reflecting and absorbing regions.
[0365] Other suitable variations of display screens include various
types of liquid-crystal displays including liquid-crystal character
display modules, thin film transistor liquid-crystal displays,
and/or any other suitable display screens. Liquid crystal character
display modules are flat-panel displays which use the
light-modulating properties of liquid crystals in order to produce
images in color or monochrome by using a backlight or a reflector.
Thin film transistor liquid-crystal displays use thin-film
transistor technology to provide for improved image qualities
including, but not limited to, contrast. Additional types of
display screens comprise touch screen capable screens and/or active
matrix backplanes comprising an amorphous silicon semiconductor or
a polythiophene semiconductor, for example.
[0366] Referring primarily to FIG. 59, the power module 11200 is
attached to the handle assembly 11000 in a first orientation. When
the power module 11200 is positioned in the first orientation, a
first maximum level of power is supplied to the surgical instrument
system. As seen in FIG. 59, the surgical instrument system
comprises a pistol grip when the power module 11200 is attached to
the surgical instrument. Still referring to FIG. 59, the power
module 11200 comprises at least a first battery 11230 and a second
battery 11260. Referring to FIG. 60, the power module 11300
comprises a housing 11310 which is configured to attach the power
module 11300 to the handle assembly 11000 in a second orientation.
The second orientation of the power module 11300 is configured to
supply an appropriate amount of power when the surgical instrument
comprises a pencil or wand grip configuration. The power module
11200 is configured to supply more power to the surgical instrument
when the power 11200 is in the first orientation, and the power
module 11300 is configured to supply less power to the surgical
instrument in the second orientation. The use of various power
modules ensures that the necessary amount of power for the
operation of the surgical instrument system is provided. With
respect to FIGS. 60-62, the drive module 11100 comprises the same
and/or similar components as the drive module 1100 discussed in
detail above with respect to FIGS. 7-9. That is, the drive module
11100 interacts with each of the shaft assemblies 12000, 13000,
14000, and 15000 in the same and/or a similar manner as the drive
module 1100 interacts with the shaft assemblies 2000, 3000, 4000,
and 5000.
[0367] FIGS. 63-65 illustrate the surgical instrument system
comprising the power module 11300 in the first orientation for use
with the scissor grip configuration of the shaft assembly 14000.
The surgical instrument system illustrated in FIGS. 63-65 is
similar in some aspects to the surgical instrument system
illustrated in FIGS. 45-47, which is discussed in greater detail
above and is also configured for use with the power module 11300
which comprises the display unit 11440'. Various surgical
instruments described herein are compatible with the power modules
11200 and 11300.
[0368] Turning now to FIG. 66, a surgical instrument system can
comprise a variety of handle assemblies such as a pencil grip
handle, a scissor grip handle, a pistol grip handle, among others,
and a shaft assembly, such as the shaft assembly 20000, for
example, that can be used with each of the handle assemblies. The
surgical instrument system comprises a first handle assembly 21000,
which is a pencil grip handle. Referring primarily to FIGS. 66A and
68A, the first handle assembly 21000 comprises one electric drive
motor, a first drive shaft 21100, and a first set of controls which
controls the one electric drive motor. The drive shaft 21100 of the
one drive motor is configured to be coupled with a drive system of
the shaft assembly 20000 when the shaft assembly 20000 is attached
to the handle assembly 21000. The drive motor used in connection
with the surgical instrument system of FIG. 66 is similar in many
respects to other motors discussed in detail above, such as the
motor 1610, for example. The first handle assembly 21000 further
comprises a plurality of electrical contacts 21022 for placing the
handle assembly 21000 in electrical communication with the shaft
assembly 20000 via electrical contacts 20022 defined thereon.
Referring to FIGS. 66 and 66A, the first handle assembly 21000
further comprises an insertable power module 21020 at the proximal
end of the handle assembly 21000.
[0369] The surgical instrument system further comprises a second
handle assembly 22000, which is a scissors grip handle. Referring
primarily to FIG. 66B, the second handle assembly 22000 comprises
first and second electric drive motors, a drive shaft 22100, a
second drive shaft 22200, a first set of controls which controls
the first drive motor, and a second set of controls which controls
the second drive motor. The first drive shaft 22100 and the second
drive shaft 22200 of the first and second drive motors can be
coupled with two drive systems of the shaft assembly 20000. The
first and second drive motors are similar in many respects to other
motors discussed in detail above, such as the motor 1610, for
example. The second handle assembly 22000 further comprises a
plurality of electrical contacts 22022 for placing the handle
assembly 22000 in electrical communication with the shaft assembly
20000 via electrical contacts 20022 defined thereon as seen in FIG.
66D. Referring primarily to FIGS. 66 and 66B, the second handle
assembly 22000 further comprises an insertable power module 22020
at the proximal end of the handle assembly 22000.
[0370] Referring to FIGS. 66 and 66C, the surgical instrument
system further comprises a third handle assembly 23000, which is a
pistol grip handle. The third handle assembly 23000 comprises
first, second, and third electric drive motors, a first drive shaft
23100, a second drive shaft 23200, a third drive shaft 23300, a
first set of controls which controls the first drive motor, a
second set of controls which controls the second drive motor, and a
third set of controls which controls the third drive motor. The
third handle assembly 23000 comprises a third set of controls. The
first drive shaft 23100, the second drive shaft 23200, and the
third drive shaft 23300 can be coupled with the three drive systems
of the shaft assembly 20000. The third handle assembly 23000
further comprises a plurality of electrical contacts 23022 for
placing the handle assembly 23000 in electrical communication with
the shaft assembly 20000 via electrical contacts 20022 defined
thereon as seen in FIGS. 66C and 66G. The third handle assembly
23000 further comprises an insertable power module 23020 at the
proximal end of the handle assembly 23000.
[0371] Further to the above, the shaft assembly 20000 comprises
three drive systems which are drivable by a drive motor of a handle
assembly--this is, of course, assuming that the handle assembly
that the shaft assembly 20000 is attached to has a sufficient
number of drive motors to drive all three drive systems of the
shaft assembly 20000. Stated another way, the first handle assembly
21000 has only one drive motor to drive one of the drive systems of
the shaft assembly 20000 and, similarly, the second handle assembly
22000 has only two drive motors to drive two of the drive systems
of the shaft assembly 20000. Thus, two drive systems of the shaft
assembly 20000 cannot be driven by the first handle assembly 21000
and one drive system of the shaft assembly 20000 cannot be driven
by the second handle assembly 22000. In various instances, the
undriven system, or systems, of the shaft assembly 20000 can remain
inert while the other drive system, or systems, of the shaft
assembly 20000 are being used. In at least one embodiment, the
handle assemblies 21000 and 22000 can be configured to lock out the
drive systems of the shaft assembly 20000 that aren't being used.
In at least one instance, the handle assembly 21000 comprises two
stationary posts extending therefrom which engage the second and
third drive systems of the shaft assembly 20000 when the shaft
assembly 20000 is assembled to the handle assembly 21000. The
stationary posts prevent the second and third drive systems of the
shaft assembly 20000 from being unintentionally actuated.
Similarly, the handle assembly 22000 comprises one stationary post
extending therefrom which engages the third drive system of the
shaft assembly 20000 to prevent the third drive system from being
unintentionally actuated. The third handle assembly 23000 does not
comprise stationary posts to lock a drive system of the shaft
assembly 20000 as all three drive systems of the shaft assembly
20000 are coupled to a drive motor in the third handle assembly
23000.
[0372] In addition to or in lieu of the above, the shaft assembly
20000 can comprise a second lock that is biased into a locked
configuration to lock the second drive system in place and a third
lock that is biased into a locked configuration to lock the third
drive in place. When the shaft assembly 20000 is attached to the
first handle assembly 21000, the shaft assembly 20000 does not
receive electrical power from the first handle assembly 21000 to
unlock the second lock or the third lock. When the shaft assembly
20000 is attached to the second handle assembly 22000, the shaft
assembly 20000 receives electrical power from the second handle
assembly 22000, via the electrical contacts 22022, and the second
lock is unlocked so that the second drive system of the shaft
assembly 20000 can be used by the second handle assembly 22000.
That said, the second handle assembly 22000 does not receive
electrical power from the second handle assembly 22000 to unlock
the third lock as the second and third locks are part of separate
and distinct circuits. When the shaft assembly 20000 is attached to
the third handle assembly 23000, the shaft assembly 20000 receives
power from the third handle assembly 23000, via the electrical
contacts 23022, to unlock the second and third locks so that the
second and third drive systems of the shaft assembly 20000 can be
used by the third handle assembly 23000.
[0373] As discussed above and referring to FIG. 66, the shaft
assembly 20000 is selectively attachable to the first handle
assembly 21000, the second handle assembly 22000, and the third
handle assembly 23000. That being said, the handle assemblies
21000, 22000, and 23000 are all configured to be held differently
by a clinician. The pen configuration of the first handle assembly
21000 is configured to be held, or pinched, between the clinician's
thumb and index finger on one hand. The scissors configuration of
the second handle assembly 22000 is configured to be gripped by an
outstretched hand of the clinician. The pistol configuration of the
third handle assembly 23000 is configured to be gripped by a
closed, clenched hand of the clinician. As a result, the handle
configurations 21000, 22000, and 23000 can be configured such that
the shaft assembly 20000 is attached thereto in different
orientations to match the grip orientation of the clinician's hand.
For instance, the shaft assembly 20000 is attached to the handle
assembly 21000 in a first orientation and attached to the shaft
assemblies 22000 and 23000 in a second orientation which is rotated
90 degrees from the first orientation. Such an arrangement matches
the typical expectations of the clinician regarding the orientation
of the shaft assembly 20000 relative to their hand. Similarly, the
first set of controls on the first handle assembly 21000 for
controlling the first drive motor can be oriented 90 degrees
relative to the orientation of the first set of controls on the
second handle assembly 22000 and the third handle assembly 23000.
Moreover, it can be desirable for a certain function of the shaft
assembly 20000 to be always coupled to a motor-driven drive system
regardless of the handle assembly that it is attached to. To
achieve this, in various instances, the shaft assembly 20000 may
have to be attached to the handles 21000, 22000, and 23000 in
different orientations to align the articulation drive system, for
example, to a motor-driven drive system.
[0374] Further information regarding the different configurations
of the handle assemblies 21000, 22000, and 23000 are presented in
FIG. 69. For example, the pencil handle assembly 21000 comprises a
motor-driven output which is configured to enable right and left
articulation of the shaft 20400. The end effector can be manually
rotated relative to the shaft 20400. The pencil handle assembly
21000 is not configured to perform any actuation motions of the end
effector or rotation of the shaft 20400 as it does not comprise a
motor driven output for the actuation motions of the end effector
or the rotation of the shaft 20400. As another example, the scissor
grip handle assembly 22000 comprises a motor-driven output which is
configured to enable right and left articulation of the shaft
20400. The scissor grip handle assembly 22000 comprises another
motor-driven output which is configured to enable a first actuation
motion of the end effector. The scissor grip handle assembly 22000
is not configured to perform a second actuation motion of the end
effector or rotation of the shaft 20400 as it does not comprise a
motor-driven output for the second actuation motion of the end
effector or the rotation of the shaft 20400. As another example,
the pistol handle assembly 23000 comprises motor-driven outputs
which are configured to enable right and left articulation of the
shaft 20400. The pistol handle assembly also comprises motor-driven
outputs which are configured to enable the first and second
actuation motions of the end effector as well as rotation of the
shaft 20400 via a motor and a shiftable transmission.
[0375] Referring primarily to FIGS. 66D and 68D, a handle assembly
24000, which is similar to the handle assembly 22000 in many
respects, comprises at least one spring loaded pin 24024 which is
configured to flex to allow the shaft assembly 20000 to be
releasably held to the shaft assembly 20000. Such an arrangement
can be adapted to the handle assemblies 21000, 22000, and 23000 to
releasably hold the shaft assembly 20000 thereto. Similar to the
handle assembly 22000, the handle assembly 24000 comprises a set of
electrical contacts 24022, a first drive shaft 24100, and a second
drive shaft 24200.
[0376] As discussed above, the shaft assembly 20000 comprises a
first drive shaft 20100, a second drive shaft 20200, and a third
drive shaft 20300, each of which enables a particular function of
the surgical instrument system by establishing a mechanical
connection with a drive shaft in any one of the handle assemblies
21000, 22000, and 23000--so long as the handle assembly has a
sufficient number of drives to be coupled to. While the shaft
assembly 20000 is attached to the first handle assembly 21000,
certain functions of the surgical instrument and/or the end
effector are enabled and certain functions of the surgical
instrument and/or the end effector are locked out as seen in FIG.
69 and described in greater detail above. For example, the first
handle assembly 21000 can drive the articulation system of the
shaft 20400 with its one drive motor. All other functions of the
shaft assembly 20000 would have to be performed by the manual
manipulation of the first handle assembly 21000. Referring
primarily to FIG. 66, the pencil grip configuration of the handle
assembly 21000 does not afford a motor-driven output for actuating
the end effector and/or rotating the shaft 20400.
[0377] The second handle assembly 22000 comprises two motors
configured to drive two of the drives of the shaft assembly 20000.
While the shaft assembly 20000 is attached to the second handle
assembly 22000, certain functions of the surgical instrument and/or
the end effector are enabled and certain functions of the surgical
instrument and/or the end effector are locked out as seen in Table
A of FIG. 69 and described in greater detail above. The first motor
of the second handle assembly 22000 drives the articulation drive
of the shaft assembly 20000 and the second motor of the second
handle assembly 22000 drives a jaw assembly of the shaft assembly
20000 to move the jaw assembly between open and closed
configurations. The third function of the shaft assembly 20000,
i.e., the rotation of the jaw assembly about a longitudinal axis
must be performed manually by rotating the second handle assembly
22000 about the longitudinal axis. The third handle assembly 23000
comprises three motors configured to drive all three of the drives
of the shaft assembly 20000. While the shaft assembly 20000 is
attached to the third handle assembly 23000 in the third
orientation, none of the functions of the surgical instrument
and/or the end effector are locked out as seen in Table A of FIG.
69 and described in greater detail above.
[0378] Referring to FIG. 70, the third handle assembly 23000
comprises a pistol grip configured for use with a smoke evacuation
tube 23400. The smoke evacuation tube 23400 is configured to fit
inside a groove 23420 within the handle assembly 23000. The shaft
assembly 20000 further comprises a smoke evacuation tube 20410
which fits over the shaft 20400. Referring to FIG. 71, the third
handle assembly 23000 comprises a first motor 23062 configured to
power the right and left articulation of the end effector. The
third handle assembly comprises a second motor configured to power
the jaw drive of the shaft assembly 20000. The third handle
assembly 23000 comprises a third motor configured to power the
rotation of the end effector about the longitudinal axis. The
handle assembly 23000 further comprises a first gear box 23064 to
reduce the speed of the first motor and a second gear box 23068 to
reduce the speed of the second motor. Still referring to FIG. 71,
the insertable power module 23020 comprises at least two battery
cells 23040 and 23050.
[0379] Referring to FIG. 72, the second handle assembly 22000
comprises a scissor grip configuration for use with a smoke
evacuation tube 22400. The smoke evacuation tube 22400 is
configured to fit inside a groove 22420 within the handle assembly
22000. Referring to FIG. 73, the handle assembly 22000 comprises a
first motor 22062 and a second motor 22066 which are configured to
power certain functions of the surgical instrument system as
discussed above. Referring to FIG. 73B for example, the first motor
22062 is configured to power right and left articulation of the end
effector, for example. The second motor 22066 is configured to
power the jaw drive of the shaft assembly 20000. When the handle
assembly 22000 is in use, the rotation of the end effector is
performed manually by the clinician. The handle assembly 22000
further comprises a first speed reduction gear box 22064 and a
second speed reduction gear box 22068 disposed within the handle
assembly 22000. Still referring to FIG. 73, the insertable power
module 22020 comprises at least two battery cells 22040 and
22050.
[0380] Referring to FIG. 74, the first handle assembly 21000
comprises a pencil grip configured for use with a smoke evacuation
tube 21400. The smoke evacuation tube 21400 is configured to fit
inside a groove 21420 within the handle assembly 21000. The shaft
assembly 20000 further comprises a smoke evacuation tube 20410
which fits over the shaft 20400. Referring to FIG. 75, the handle
assembly 21000 comprises a motor 21062 which is configured to power
the right and left articulation of the end effector. When the
handle assembly 21000 is in use, the rotation of the end effector
is performed manually by the clinician, and certain functions such
as a first actuation motion and a second actuation motion of the
end effector are locked out as seen in FIG. 75B. The handle
assembly 21000 further comprises a speed reduction gear box 21064
disposed within the handle assembly 21000. Still referring to FIG.
75, the insertable power module 21020 comprises at least two
battery cells 21040 and 21050.
[0381] Referring to FIG. 77, various surgical instrument systems
described herein comprise one or more feedback systems which are
configured to alert the clinician as to the state of the surgical
instrument system. The surgical instrument system comprises a
handle assembly 26000 which includes a first drive 26100, a second
drive 26200, and a third drive 26300 which are configured to permit
drive systems within the handle assembly 26000 to be operably
coupled to the drive systems of a shaft assembly 27000. The shaft
assembly 27000 is similar to the shaft assembly 20000 in many
respects. The handle assembly 26000 further comprises a plurality
of electrical contacts 26022 configured to place the handle
assembly 26000 in electrical communication with the shaft assembly
27000. The shaft assembly 27000 comprises an actuation rod 27700
extending within a shaft 27770, wherein the actuation rod 27700 is
drivable by a drive system of the handle assembly 26000. The shaft
assembly 27000 further comprises an end effector 27200 rotatably
attached to the shaft 27770 about an articulation joint 27300. The
end effector 27200 comprises a first jaw 27220 and a second jaw
27222 which are movable between open and closed positions in
response to the motions of the actuation rod 27700. The handle
assembly 26000 further comprises a curved trigger 26400 rotatably
connected to the handle assembly 26000 which, as described in
greater detail below, is used to control the drive system. The
curved trigger 26400 comprises a curved trigger rod 26500 extending
therefrom, as also discussed in greater detail below.
[0382] Referring to FIG. 79, further to the above, the handle
assembly 26000 comprises a motor control system 26010 which is
configured to run a motor 26030 configured to drive the drive
system of the shaft assembly 27000 as mentioned above. The handle
assembly 26000 further comprises a power module 26028 configured to
supply power to the motor 26030 at the direction of a motor control
system 26010. The handle assembly 26000 comprises a trigger sensor
26800 which is in communication with the motor control system 26010
and is configured to monitor the motion of the trigger 26400. The
trigger sensor 26800 is configured to generate a voltage potential
which is detectable by the motor control system 26010--the
magnitude of which can be used to ascertain the actuation and/or
position of the trigger 26400. In response to the signal from the
trigger sensor 26800, the motor control system 26010 is configured
to run the motor 26030 to drive the drive rod 26050. In various
instances, the trigger sensor 26800 comprises a variable resistance
sensor, for example, and the speed of the motor 26030 is responsive
to the signal provided by the trigger sensor 26800.
[0383] As the drive rod 26050 is driven distally by the motor
26030, the drive rod 26050 experiences a force load. There is a
wide range of acceptable force loads that the drive rod 26050 may
experience during use. That said, such force loads can suggest
certain information about the performance of the surgical system.
For instance, force loads toward the top of the acceptable range
can indicate that thick and/or dense tissue is captured within the
end effector 27200 while force loads toward the bottom of the
acceptable range can indicate that thin and/or less dense tissue is
captured within the end effector 27200, for example. Without more,
this information is not conveyed to the clinician as the trigger
26400 is not mechanically coupled to the drive rod 26050; rather,
the trigger 26400 is electrically coupled to the motor 26030 via
the motor control system 26010. Without this information, a
clinician may not fully appreciate what is occurring within the
surgical system. To this end, the surgical instrument system
comprises means for detecting the force load experienced by the
drive rod 26050 and communicating this information to the
clinician. In at least one instance, the surgical instrument system
comprises one or more load cells and/or strain gauges configured to
detect the force load within the drive rod 26050. In addition to or
in lieu of these mechanical detection systems, the motor control
system 26010 is configured to monitor the current drawn by the
electric motor 26030 during use and this information as a proxy for
the force load being experienced by the drive rod 26050. Referring
to FIG. 79, the handle assembly comprises a current sensor 26012 in
communication with the power control system 26020, and/or the motor
control system 26010, which is configured to monitor the amount of
current drawn by the motor 26030. Discussed below are systems which
can restore the clinician's sense for the loads being experienced
within the drive system based on the load data supplied to the
power control system 26020.
[0384] Referring to FIGS. 77A and 77B, the handle assembly 26000
further comprises an electroactive polymer (hereinafter "EAP")
26600 positioned within an aperture defined therein. The EAP 26600
is in signal communication with the power control system 26020 and
is responsive to a voltage output provided by the power control
system 26020. Referring primarily to FIG. 77B, the handle assembly
26000 comprises a curved cylinder 26900 which surrounds a portion
of the curved trigger rod 26500 of the trigger 26400. More
specifically, the curved trigger rod 26500 comprises a trigger bar
26550 extending through the curved cylinder 26900 positioned within
the handle assembly 26000. The EAP 26600 is radially constrained by
the sidewalls of the curved aperture defined in the handle 26000.
The EAP 26600 reacts to the voltage potential applied thereto by
the power control system 26020 and expands and contracts
proportionately in size to the magnitude of the force being applied
to the drive rod 26050. When the voltage applied to the EAP 26600
is increased, the walls of the handle assembly 26000 prevent the
EAP 26600 from expanding. As a result, the EAP 26600 expands toward
the trigger bar 26550 extending from the curved trigger 26500 and,
thus, applies a compressive force to the trigger bar 26550. The
compression force applied by the EAP 26600 on the trigger bar 26550
compresses the trigger bar 26550 which, in turn, creates a drag
force between the EAP 26600 and the trigger bar 26550 when the
trigger bar 26550 is moved by the trigger 26400. This drag force is
felt by the clinician pulling the trigger 26400 and directly
communicates the forces of the end effector 27200 to the clinician.
As the magnitude of the load force experienced by the drive rod
26050 increases, the voltage applied to the EAP 26600 by the power
control system 26020 increases, and the drag experienced by the
trigger 26400 also increases. As the magnitude of the load force
experienced by the drive rod 26050 decreases, the voltage applied
to the EAP 26600 by the power control system 26020 decreases, and
the drag experienced by the trigger 26400 also decreases. These
relationships are linearly proportional; however, any proportional
relationship could be used. Moreover, further to the above, the
magnitude of the voltage potential applied to the EAP 26600 by the
power control system 26020 is proportionately coupled to the motor
current drawn by the motor 26030, the voltage supplied by the load
cell circuit, and/or the voltage supplied by the strain gauge
circuit, for example.
[0385] Turning to FIG. 78A, the EAP 26600 is shown in a
non-energized state before the voltage potential is applied to the
EAP 26600. As seen in FIG. 78A, there is space defined between the
EAP 26600 within the curved cylinder 26900 and the curved trigger
26500. Referring to FIG. 78B, as the voltage potential is applied
to the EAP 26600, the EAP 26600 constricts the trigger bar 26550 of
the curved trigger 26500 which creates the drag force discussed
above. The relationship between the forces on the end effector
27200 and/or the shaft 27770 and the compressive force on the
curved trigger 26500 is further illustrated in FIGS. 80 and 81.
[0386] Referring to FIG. 80, L.sub.1 illustrates the torque
experienced by the motor drive shaft. L.sub.2 illustrates the load
force experienced by the drive rod 26050. L.sub.3 illustrates the
voltage applied to the EAP 26600. The load force on the drive rod
26050 and the torque on the motor drive shaft are proportional to
the amount of voltage applied to the EAP 26600. That is, as the
load force and torque increase, as illustrated by way of L.sub.1
and L.sub.2 in FIG. 80, the voltage applied to the EAP 26600 also
increases. Further to the above, there is a proportional
relationship between the compressive force applied to the trigger
26500 and the voltage applied to the EAP 26600. As the voltage
applied to the EAP 26600 increases, the drag force on the trigger
26500 increases, as discussed in greater detail above. The voltage
applied to the EAP 26600 increases as a reaction to the amount of
current flowing through the motor 26030 which is an indicator of
the forces on the drive rod 26050 and the torques on the motor
drive shaft. Referring to FIG. 81, L.sub.4 illustrates the change
in the voltage potential applied to the EAP 26600 over time.
[0387] Turning to FIG. 86, additional feedback systems similar to
those are configured for use with suturing devices. In particular,
various surgical instrument systems are equipped with programs
which are capable of measuring bending and axial loads applied to a
suturing device shaft such as the shaft 28100 of the suturing
device 28000 illustrated in FIG. 86. The suturing device 28000
comprises at least one motor configured to provide power to the
suturing device during a surgical procedure. The suturing device
28000 further comprises a distal head 28300 rotatably connected to
the shaft 28100 by an articulation joint 28200. The handle of the
suturing device 28000 comprises a display which is configured to
indicate a predefined proportion of loads to a user. The surgical
instrument systems described herein are also configured for use
with robotic surgical systems as well as cloud-based technology.
Various applications disclosed which are incorporated by reference
disclose situational awareness of an interactive HUB system which
is configured to define various surgical steps. The devices,
systems, and methods disclosed in the Subject Application can also
be used with the devices, systems, and methods disclosed in U.S.
Provisional Patent Application No. 62/659,900, entitled METHOD OF
HUB COMMUNICATION, filed on Apr. 19, 2018, U.S. Provisional Patent
Application No. 62/611,341, entitled INTERACTIVE SURGICAL PLATFORM,
filed on Dec. 28, 2017, U.S. Provisional Patent Application No.
62/611,340, entitled CLOUD-BASED MEDICAL ANALYTICS, filed on Dec.
28, 2017, and U.S. Provisional Patent Application No. 62/611,339,
entitled ROBOT ASSISTED SURGICAL PLATFORM, filed on Dec. 28, 2017,
which are incorporated by reference in their entireties herein.
Such surgical steps include providing the handle of the suturing
device 28000 with and updated ration of the amount of the load
being exerted as a portion of the suture stitch or knot tension.
The tension is used by the user to create more standardization of
the stitch to stitch tightness. Further uses are contemplated which
include instructional uses for new users of the surgical instrument
systems described herein. FIG. 87 further illustrates the
relationship between the forces applied to the shaft 28100 and the
distal head 28300 based on the different motors (e.g. the motor
supplying power to perform an actuation motion of an end effector
and the motor supplying power to perform a distal head rotation
motion).
[0388] The surgical instrument systems discussed in greater detail
above are configured for use with locking and safety mechanisms.
The locking mechanisms comprise electrical sensing means configured
to detect whether a modular attachment is in a usable or unusable
state. The locking mechanisms further comprise electrical sensing
means configured to detect whether a loadable mechanism is in a
usable or unusable state. FIG. 82 illustrates an exemplary shaft
assembly 30000 which is similar to the shaft assembly 20000. The
locking mechanisms which will be discussed in greater detail below
are configured for use with any of the surgical instrument systems
described herein. The shaft assembly 30000 comprises a drive 30100,
a second drive 30200, and a third drive 30300. The shaft assembly
30000 comprises a plurality of electrical contacts 30022 configured
to place the shaft assembly 30000 in electrical communication with
any of the handle assemblies described herein upon being attached
thereto. The shaft assembly 30000 further comprises an on-board
control circuit 30500. One example of a single use lockout 30400 is
illustrated in FIG. 83. The single use lockout comprises a lock
solenoid 30410, a lock spring 30420, and a lock pin 30430 as seen
in FIGS. 84 and 85. The lock solenoid 30410 is energized upon power
being supplied to the shaft assembly 30000.
[0389] In such instances, the lock solenoid 30410 is configured to
push the lock pin 30430 outwardly into a locked position; however
the lock pin 30430 is held in a staged position until the shaft
assembly 30000 is detached from the handle. At such point, the lock
spring 30420 can push the lock pin 30430 from its staged position
into its locked position. In various instances, the shaft assembly
30000 comprises a lock shoulder 30440 configured to hold the lock
pin 30430 in its locked position and prevent the lock pin 30430
from being reset. In such instances, the lock pin 30430 protrudes
proximally from the housing of the shaft assembly 30000 which
prevents the shaft assembly 30000 from being reattached to a
handle. While the solenoid 30410 can drive the lock pin 30430 into
its locked position in certain instances; in other instances, the
solenoid 30410 holds the lock pin 30430 in its unlocked position
until energized by the attachment of the shaft assembly 30000 to
the handle wherein, at such point, the solenoid 30410 can release
the lock pin 30430 such that the lock spring 30420 can move the
lock pin 30430 into its staged position where the shaft assembly
30000 is attached to the handle and into its locked position once
the shaft assembly 30000 is removed from the handle.
[0390] Other lockout mechanisms comprise a locking member which
immobilizes a drive shaft of a surgical instrument if a modular
shaft is attached to an incompatible handle can be used. For
example, when a scissor grip handle is attached to an articulating
clip applier shaft with distal head rotation, a lockout prevents
distal head rotation drive because the scissor grip handle is used
for only one drive system which is often the clip drive. In various
instances, the lockout fixes the rotation of the distal head by
engaging a lockout member into the drive shaft at the proximal end
of the shaft. An additional locking mechanism for use with the
surgical instrument systems described herein comprises a distal
locking mechanism which prevents actuation motions of a clip
applier or suturing device if a loaded cartridge is not in the
jaws. A similar lockout mechanism comprises a distal locking
mechanism which prevents actuation motions of a clip applier or
suturing device if a spent cartridge is positioned in the jaws. The
distal locking mechanism further comprises a means for sensing the
engagement state of the distal lockout through a power system of
the surgical instrument in order to prevent the activation of the
motor or to instruct the motor to provide haptic vibration feedback
that the handle assembly is incompatible with the attachment
portion. Additional lockout assemblies include a modular lockout
which prohibits or changes the operation of the motor if the shaft
is detected to be in an unusable state.
[0391] Turning now to FIG. 88, an exemplary system for identifying
the components of a surgical instrument system is disclosed. Step
32100 comprises attaching a shaft module to a handle assembly. Step
32200 comprises attaching a battery to a handle assembly. Step
32300 comprises energizing a safety circuit or watchdog processor
wherein either is compatible with surgical instrument systems
discussed in greater detail above. Decision 32400 comprises the
verification of the integrity of the electrical circuit within the
surgical instrument system. If the integrity of the circuit is bad,
then the system is configured to display an error signal and shut
down in step 32410. If the integrity of the circuit is good, the
system is configured to identify and log a serial number associated
with a handle assembly, battery, and/or shaft assembly, as
illustrated in step 32420. Decision 32500 is configured to identify
the type of handle assembly. For example, if the handle assembly is
a simple scissors handle, the system is configured to control a
program for a simple mechanism configuration which includes a shaft
rotation lockout, as illustrated in step 32500. If the system
determines that the handle assembly is not a simple scissors
handle, then the system is configured to verify the functionality
of all instrument mechanisms as illustrated in step 32510.
[0392] With further reference to FIG. 88, once the system
identifies the type of handle assembly, the system is configured to
determine whether the shaft assembly comprises a loadable portion
in decision 32600, and is further configured to determine the
status of the loadable portion. If the loadable portion is
unloaded, the system is configured to generate an error message in
step 32610 which indicates that the system is waiting for the
loadable portion to be reloaded before a surgical procedure can
continue. If the loadable portion is loaded, the system is
configured detect whether a display unit is present during decision
32700. If the surgical instrument does not comprise a display unit,
for example, the system is configured use a simple green light to
indicate that the surgical instrument is ready for use. If the
surgical instrument comprises a display unit, for example, the
system configures the display unit for use with whatever shaft
assembly is attached to the surgical instrument in step 32720.
Additional systems comprise the identification of various
compatible shaft assemblies and handle assemblies. Other systems
comprise the identification of the status of a power module and the
status of the power module. The verification processes described
above are configured for use with any of the surgical instrument
systems described herein. The surgical instruments, modules,
systems, and methods disclosed herein can be used with the various
disclosures incorporated by reference. The devices, systems, and
methods disclosed in the Subject Application can also be used with
the devices, systems, and methods disclosed in U.S. Provisional
Patent Application No. 62/659,900, entitled METHOD OF HUB
COMMUNICATION, filed on Apr. 19, 2018, U.S. Provisional Patent
Application No. 62/611,341, entitled INTERACTIVE SURGICAL PLATFORM,
filed on Dec. 28, 2017, U.S. Provisional Patent Application No.
62/611,340, entitled CLOUD-BASED MEDICAL ANALYTICS, filed on Dec.
28, 2017, and U.S. Provisional Patent Application No. 62/611,339,
entitled ROBOT ASSISTED SURGICAL PLATFORM, filed on Dec. 28, 2017,
which are incorporated by reference in their entireties herein.
[0393] The surgical instrument systems described herein are
motivated by an electric motor; however, the surgical instrument
systems described herein can be motivated in any suitable manner.
In certain instances, the motors disclosed herein may comprise a
portion or portions of a robotically controlled system. U.S. patent
application Ser. No. 13/118,241, entitled SURGICAL STAPLING
INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S.
Pat. No. 9,072,535, for example, discloses several examples of a
robotic surgical instrument system in greater detail, the entire
disclosure of which is incorporated by reference herein.
[0394] The surgical instrument systems described herein can be used
in connection with the deployment and deformation of staples.
Various embodiments are envisioned which deploy fasteners other
than staples, such as clamps or tacks, for example. Moreover,
various embodiments are envisioned which utilize any suitable means
for sealing tissue. For instance, an end effector in accordance
with various embodiments can comprise electrodes configured to heat
and seal the tissue. Also, for instance, an end effector in
accordance with certain embodiments can apply vibrational energy to
seal the tissue. In addition, various embodiments are envisioned
which utilize a suitable cutting means to cut the tissue.
[0395] The entire disclosures of:
[0396] U.S. patent application Ser. No. 11/013,924, entitled TROCAR
SEAL ASSEMBLY, now U.S. Pat. No. 7,371,227;
[0397] U.S. patent application Ser. No. 11/162,991, entitled
ELECTROACTIVE POLYMER-BASED ARTICULATION MECHANISM FOR GRASPER, now
U.S. Pat. No. 7,862,579;
[0398] U.S. patent application Ser. No. 12/364,256, entitled
SURGICAL DISSECTOR, now U.S. Patent Application Publication No.
2010/0198248;
[0399] U.S. patent application Ser. No. 13/536,386, entitled EMPTY
CLIP CARTRIDGE LOCKOUT, now U.S. Pat. No. 9,282,974;
[0400] U.S. patent application Ser. No. 13/832,786, entitled
CIRCULAR NEEDLE APPLIER WITH OFFSET NEEDLE AND CARRIER TRACKS, now
U.S. Pat. No. 9,398,905;
[0401] U.S. patent application Ser. No. 12/592,174, entitled
APPARATUS AND METHOD FOR MINIMALLY INVASIVE SUTURING, now U.S. Pat.
No. 8,123,764;
[0402] U.S. patent application Ser. No. 12/482,049, entitled
ENDOSCOPIC STITCHING DEVICES, now U.S. Pat. No. 8,628,545;
[0403] U.S. patent application Ser. No. 13/118,241, entitled
SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT
ARRANGEMENTS, now U.S. Pat. No. 9,072,535;
[0404] U.S. patent application Ser. No. 11/343,803, entitled
SURGICAL INSTRUMENT HAVING RECORDING CAPABILITIES, now U.S. Pat.
No. 7,845,537;
[0405] U.S. patent application Ser. No. 14/200,111, entitled
CONTROL SYSTEMS FOR SURGICAL INSTRUMENTS, now U.S. Pat. No.
9,629,629;
[0406] U.S. patent application Ser. No. 14/248,590, entitled MOTOR
DRIVEN SURGICAL INSTRUMENTS WITH LOCKABLE DUAL DRIVE SHAFTS, now
U.S. Pat. No. 9,826,976;
[0407] U.S. patent application Ser. No. 14/813,242, entitled
SURGICAL INSTRUMENT COMPRISING SYSTEMS FOR ASSURING THE PROPER
SEQUENTIAL OPERATION OF THE SURGICAL INSTRUMENT, now U.S. Patent
Application Publication No. 2017/0027571;
[0408] U.S. patent application Ser. No. 14/248,587, entitled
POWERED SURGICAL STAPLER, now U.S. Pat. No. 9,867,612;
[0409] U.S. patent application Ser. No. 12/945,748, entitled
SURGICAL TOOL WITH A TWO DEGREE OF FREEDOM WRIST, now U.S. Pat. No.
8,852,174;
[0410] U.S. patent application Ser. No. 13/297,158, entitled METHOD
FOR PASSIVELY DECOUPLING TORQUE APPLIED BY A REMOTE ACTUATOR INTO
AN INDEPENDENTLY ROTATING MEMBER, now U.S. Pat. No. 9,095,362;
[0411] International Application No. PCT/US2015/023636, entitled
SURGICAL INSTRUMENT WITH SHIFTABLE TRANSMISSION, now International
Patent Publication No. WO 2015/153642 A1;
[0412] International Application No. PCT/US2015/051837, entitled
HANDHELD ELECTROMECHANICAL SURGICAL SYSTEM, now International
Patent Publication No. WO 2016/057225 A1;
[0413] U.S. patent application Ser. No. 14/657,876, entitled
SURGICAL GENERATOR FOR ULTRASONIC AND ELECTROSURGICAL DEVICES, U.S.
Patent Application Publication No. 2015/0182277;
[0414] U.S. patent application Ser. No. 15/382,515, entitled
MODULAR BATTERY POWERED HANDHELD SURGICAL INSTRUMENT AND METHODS
THEREFOR, U.S. Patent Application Publication No. 2017/0202605;
[0415] U.S. patent application Ser. No. 14/683,358, entitled
SURGICAL GENERATOR SYSTEMS AND RELATED METHODS, U.S. Patent
Application Publication No. 2016/0296271;
[0416] U.S. patent application Ser. No. 14/149,294, entitled
HARVESTING ENERGY FROM A SURGICAL GENERATOR, U.S. Pat. No.
9,795,436;
[0417] U.S. patent application Ser. No. 15/265,293, entitled
TECHNIQUES FOR CIRCUIT TOPOLOGIES FOR COMBINED GENERATOR, U.S.
Patent Application Publication No. 2017/0086910; and
[0418] U.S. patent application Ser. No. 15/265,279, entitled
TECHNIQUES FOR OPERATING GENERATOR FOR DIGITALLY GENERATING
ELECTRICAL SIGNAL WAVEFORMS AND SURGICAL INSTRUMENTS, U.S. Patent
Application Publication No. 2017/0086914, are hereby incorporated
by reference herein.
EXAMPLES
Example 1
[0419] A surgical instrument system comprising a handle, and a
shaft. The handle comprises a housing, a motor disposed within the
handle, at least one control switch, and a motor-control processor
in communication with the at least one control switch to control
the motor, wherein the processor is not positioned in the handle.
The surgical instrument system also comprises a disposable battery
housing configured to be attached to the housing. The disposable
battery housing comprises a disposable battery and a display
unit.
Example 2
[0420] The surgical instrument system of Example 1, further
comprising a controller.
Example 3
[0421] The surgical instrument system of Example 2, wherein the
controller is located within the shaft.
Example 4
[0422] The surgical instrument system of Examples 2 or 3, wherein
the controller comprises a control circuit configured to control
the display unit on the disposable battery housing.
Example 5
[0423] The surgical instrument system of Examples 1, 2, 3, or 4,
wherein the display unit on the disposable battery housing is touch
screen capable.
Example 6
[0424] The surgical instrument system of Examples 1, 2, 3, 4, or 5,
wherein the display unit comprises a multi-color display configured
to indicate at least one function of the surgical instrument system
to a user.
Example 7
[0425] A surgical instrument comprising a handle, a shaft, and a
disposable power module. The handle comprises a housing, a motor
located in the handle, and at least one control switch. The
disposable power module comprises a disposable battery and a
display unit. The surgical instrument also comprises a
motor-control processor in communication with the at least one
control switch to control the motor, wherein the processor is
positioned in at least one of the shaft and the disposable power
module.
Example 8
[0426] The surgical instrument of Example 7, further comprising a
controller.
Example 9
[0427] The surgical instrument of Example 8, wherein the controller
is located within the shaft.
Example 10
[0428] The surgical instrument of Examples 8 or 9, wherein the
controller comprises a control circuit configured to control the
display unit on the disposable power module.
Example 11
[0429] The surgical instrument of Examples 7, 8, 9, or 10, wherein
the display unit on the disposable power module is touch screen
capable.
Example 12
[0430] The surgical instrument of Examples 7, 8, 9, 10, or 11,
wherein the display unit comprises a multi-color display configured
to indicate at least one function of the surgical instrument.
Example 13
[0431] A surgical instrument comprising a housing, a handle
attached to the housing, an end effector, a shaft, and a disposable
battery comprising a multi-color display unit. The handle comprises
a motor and at least one control switch. The shaft comprises a
controller located within the shaft, wherein the controller is
configured to control at least one function of the end
effector.
Example 14
[0432] The surgical instrument of Example 13, wherein the
controller comprises a control circuit configured to control the
display unit on the disposable battery.
Example 15
[0433] The surgical instrument of Examples 13 or 14, wherein the
end effector further comprises at least one sensor.
Example 16
[0434] The surgical instrument of Examples 13, 14, or 15, wherein
the display unit on the disposable battery is touch screen
capable.
Example 17
[0435] A sterilizable surgical instrument system comprising a
handle assembly, a shaft attached to the distal end of the handle
assembly, a disposable battery assembly, and an end effector
attached to a distal end of the shaft. The handle assembly
comprises a motor and at least one control switch. The shaft
comprises a controller located within the shaft. The disposable
battery assembly comprises a disposable battery and a display
unit.
Example 18
[0436] The surgical instrument system of Example 17, wherein the
controller comprises a control circuit configured to control the
display unit on the disposable battery.
Example 19
[0437] The surgical instrument system of Examples 17 or 18, wherein
the end effector further comprises at least one sensor.
Example 20
[0438] The surgical instrument system of Examples 17, 18, or 19,
wherein the display unit on the disposable battery housing is touch
screen capable.
Example 21
[0439] The surgical instrument system of Examples 17, 18, 19, or
20, wherein the display unit comprises a multi-color display
configured to indicate at least one function of the surgical
instrument system.
Example 22
[0440] A surgical instrument system comprising a handle assembly
comprising a drive system including an electric motor, a battery
comprising a first battery cell and a second battery cell, a first
shaft assembly attachable to the handle assembly, and a second
shaft assembly attachable to the handle assembly. The drive system
utilizes a first power load from the battery to operate the first
shaft assembly and the first power load is supplied by the first
battery cell and not the second battery cell. The drive system
comprises a second power load to operate the second shaft assembly
which is different than the second power load and the second power
load is supplied by the first battery cell and the second battery
cell.
Example 23
[0441] A surgical instrument system comprising a handle assembly
and a battery. The handle assembly comprises a housing and a drive
system including an electric motor. The battery is insertable into
the housing in a first orientation and a second orientation. The
battery is configured to supply a first maximum power to the drive
system when the battery is in the first orientation, wherein the
battery is configured to supply a second maximum power when the
battery is in the second orientation, and wherein the first
orientation is different than the second orientation.
Example 24
[0442] The surgical instrument system of Example 23, wherein the
battery is inserted into the handle in the first orientation when a
first shaft assembly is attached to the handle, and wherein the
battery is inserted into the second orientation when a second shaft
assembly is attached to the handle.
Example 25
[0443] A surgical instrument system comprising a drive module
comprising a drive module housing and a shaft assembly attachable
to the drive module housing. The surgical instrument system also
comprises a drive system and a battery attachable to the drive
module housing. The drive system comprises an electric motor
positioned in the drive module housing, a drive shaft in the shaft
assembly which is operably couplable with the electric motor when
the shaft assembly is attached to the drive module, and a control
circuit including a microprocessor, wherein the microprocessor is
positioned in the shaft assembly. The battery comprises a battery
housing, at least one battery cell in the battery housing
configured to supply power to the drive system when the battery is
attached to the drive module housing, and a display in
communication with control circuit when the battery is attached to
the drive module housing.
Example 26
[0444] The surgical instrument system of Example 25, wherein the
display comprises electrophoretic media.
Example 27
[0445] The surgical instrument system of Example 25, wherein the
display comprises an active matrix backplane.
Example 28
[0446] The surgical instrument system of Example 27, wherein the
active matrix backplane comprises an amorphous silicon
semiconductor.
Example 29
[0447] The surgical instrument system of Example 27, wherein the
active matrix backplane comprises a polythiophene
semiconductor.
Example 30
[0448] The surgical instrument system of Example 27, wherein the
display comprises an electrochromic display.
Example 31
[0449] The surgical instrument system of Example 27, wherein the
display comprises a liquid-crystal display.
Example 32
[0450] The surgical instrument system of Example 27, wherein the
display comprises a thin-film transistor liquid-crystal
display.
Example 33
[0451] A surgical instrument system comprising a drive module
comprising a drive module housing and a battery attachable to the
drive module housing. The battery comprises a battery housing, at
least one battery cell in the battery housing configured to supply
power to the drive system when the battery is attached to the drive
module housing, and a display in communication with a control
circuit when the battery is attached to the drive module housing.
The surgical instrument system also comprises a drive system, an
electric motor positioned in the drive module housing and a control
circuit including a microprocessor, wherein the microprocessor is
positioned in the battery housing.
Example 34
[0452] The surgical instrument system of Example 33, wherein the
display comprises electrophoretic media.
Example 35
[0453] The surgical instrument system of Example 33, wherein the
display comprises an active matrix backplane.
Example 36
[0454] The surgical instrument system of Example 35, wherein the
active matrix backplane comprises an amorphous silicon
semiconductor.
Example 37
[0455] The surgical instrument system of Example 35, wherein the
active matrix backplane comprises a polythiophene
semiconductor.
Example 38
[0456] The surgical instrument system of Example 33, wherein the
display comprises an electrochromic display.
Example 39
[0457] The surgical instrument system of Example 33, wherein the
display comprises a liquid-crystal display.
Example 40
[0458] The surgical instrument system of Example 33, wherein the
display comprises a thin-film transistor liquid-crystal
display.
Example 41
[0459] A surgical instrument system, comprising a drive module
comprising a drive module housing and a battery attachable to the
drive module housing. The battery comprises a battery housing, at
least one battery cell in the battery housing configured to supply
power to the drive system when the battery is attached to the drive
module housing, and a display in communication with a control
circuit when the battery is attached to the drive module housing.
The surgical instrument system also comprises a drive system, an
electric motor positioned in the drive module housing, and a
control system including a microprocessor, wherein the
microprocessor is not positioned in the drive module.
Example 42
[0460] The surgical instrument system of Example 41, wherein the
control system comprises at least one input on the drive
module.
Example 43
[0461] The surgical instrument system of Example 41, wherein the
control system comprises at least one switch on the drive
module.
Example 44
[0462] A surgical instrument system comprising a drive module
comprising a housing and an electric motor and a battery
selectively attachable to the drive module. The battery comprises a
housing comprising a connector configured to releasably connect the
battery to the drive module, at least one battery cell, and an
electronic display.
Example 45
[0463] The surgical instrument system of Example 44, wherein the
display comprises electrophoretic media.
Example 46
[0464] The surgical instrument system of Example 44, wherein the
display comprises an active matrix backplane.
Example 47
[0465] The surgical instrument system of Example 46, wherein the
active matrix backplane comprises an amorphous silicon
semiconductor.
Example 48
[0466] The surgical instrument system of Example 46, wherein the
active matrix backplane comprises a polythiophene
semiconductor.
Example 49
[0467] The surgical instrument system of Example 44, wherein the
display comprises an electrochromic display.
Example 50
[0468] The surgical instrument system of Example 44, wherein the
display comprises a liquid-crystal display.
Example 51
[0469] The surgical instrument system of Example 44, wherein the
display comprises a thin-film transistor liquid-crystal
display.
Example 52
[0470] A handle for use with a surgical instrument system, wherein
the handle comprises a drive module and a sealed battery module.
The a drive module comprises a housing and a sealed motor module
removably positionable with the housing. The sealed motor module
comprises a liquid-tight barrier, at least one electrical input
extending through the liquid-tight barrier, and a rotatable output
extending through the liquid-tight barrier. The sealed battery
module comprises a housing comprising a connector configured to
attach the sealed battery module to the drive module, a
liquid-tight battery barrier, and at least one electrical output
extending through the liquid-tight battery barrier.
Example 53
[0471] A surgical instrument system comprising a drive module
comprising a drive system including an electric motor, a shaft
attachable to the drive module, wherein the shaft comprises an end
effector configured to treat the tissue of a patient. The surgical
instrument system also comprises a battery attachable to the drive
module and at least one electronic display system on at least one
of the shaft and the battery. The surgical instrument system also
comprises a control circuit comprising a processor, wherein the
control circuit is configured to control the drive system, and
wherein the control circuit is configured to communicate with the
at least one electronic display system, and a power switch
configured to place the battery in communication with the control
circuit when the power switch is placed in an operational
configuration, wherein the processor is configured to interrogate
the shaft and the battery to assess the number of electronic
display systems in the surgical instrument system.
Example 54
[0472] The surgical instrument system of Example 53, wherein the
processor is configured to interrogate the shaft and the battery to
assess the number of electronic display systems in the surgical
instrument system when the power switch is moved into the
operational configuration.
Example 55
[0473] The surgical instrument system of Example 53, wherein the
processor is configured to interrogate the shaft and the battery to
assess the number of electronic display systems in the surgical
instrument system when the battery is assembled to the surgical
instrument system.
Example 56
[0474] A surgical instrument system comprising a drive module
comprising a drive system including an electric motor, a shaft
attachable to the drive module, wherein the shaft comprises an end
effector configured to treat the tissue of a patient, and a battery
attachable to the drive module. The surgical instrument system also
comprises at least one electronic display system on at least one of
the drive module, the shaft, and the battery and a control circuit
comprising a processor, wherein the control circuit is configured
to control the drive system, wherein the control circuit is
configured to communicate with the at least one electronic display
system, and wherein the processor is configured to interrogate the
shaft and the battery to assess the number of electronic display
systems in the surgical instrument system.
Example 57
[0475] The surgical instrument system of Example 56, wherein the
processor is configured to interrogate the drive module, the shaft,
and the battery to assess the number of electronic display systems
in the surgical instrument system when the battery is assembled to
the surgical instrument system.
Example 58
[0476] A surgical instrument system comprising a drive module
comprising a drive system including an electric motor, a shaft
attachable to the drive module, wherein the shaft comprises an end
effector configured to treat the tissue of a patient, and a battery
attachable to the drive module. The surgical instrument system also
comprises a control circuit comprising a processor, wherein the
control circuit is configured to control the drive system during an
operational sequence, and wherein the battery is configured to
supply power to the control circuit during an initiation sequence,
and a communications circuit configured to communicate with and
receive data from an off-board control system during the initiation
sequence, wherein the communications circuit is in communication
with the control circuit, wherein the control circuit is configured
to receive the data from the communications circuit, and wherein
the control circuit is configured to modify the operational
sequence using the data.
Example 59
[0477] The surgical instrument system of Example 58, wherein the
initiation sequence is initiated by the assembly of the battery to
the drive module.
Example 60
[0478] The surgical instrument system of Example 58, further
comprising a switch configurable in an operational configuration,
wherein the initiation sequence is initiated by placing the switch
in the operational configuration.
Example 61
[0479] The surgical instrument system of Example 58, wherein the
communications circuit comprises a wireless signal transmitter and
a wireless signal receiver.
Example 62
[0480] The surgical instrument system of Example 58, wherein the
operational sequence comprises an algorithm, and wherein the
control circuit modifies the algorithm when modifying the
operational sequence.
Example 63
[0481] The surgical instrument system of Example 62, wherein the
control circuit deactivates a function of the surgical instrument
system when modifying the algorithm.
Example 64
[0482] The surgical instrument system of Example 58, wherein the
initiation sequence comprises an algorithm, and wherein the control
circuit deactivates a function of the surgical instrument system
when modifying the algorithm.
Example 65
[0483] A surgical instrument system, comprising a surgical
instrument configured to perform at least three functions of an end
effector, a first motor, a second motor, a third motor, and a first
handle comprising a first number of controls, wherein each control
corresponds to one of the three functions of the end effector. The
surgical instrument system also comprises a second handle
comprising a second number of controls and a shaft assembly
attachable to the first handle and the second handle, wherein the
shaft assembly is attachable to the first handle in a first
orientation to engage one of the motors, and wherein the shaft
assembly is attachable to the second handle in a second orientation
to engage a different one of the motors, and wherein the surgical
instrument system is configured to perform a different end effector
function in the first orientation and the second orientation, and
wherein certain end effector functions are locked out based on
which motor is engaged in each orientation.
Example 66
[0484] The surgical instrument system of Example 65, wherein the
first number of controls is different than the second number of
controls.
Example 67
[0485] The surgical instrument system of Example 65 or 66, wherein
the first orientation is different than the second orientation.
Example 68
[0486] The surgical instrument system of Examples 65, 66, or 67,
wherein the first orientation prevents the surgical instrument from
performing at least one function of the end effector.
Example 69
[0487] The surgical instrument system of Examples 65, 66, 67, or
68, wherein the second orientation prevents the surgical instrument
from performing at least one function of the end effector.
Example 70
[0488] A surgical instrument system comprising a surgical
instrument configured to perform at least three functions of an end
effector and a motor operable in at least three states. The
surgical instrument system also comprises a first handle comprising
a first number of controls, wherein each control corresponds to a
function of the end effector, a motor drive, and a first attachment
portion, wherein the first attachment portion connects to the
surgical instrument in a first orientation in order to enable a
first set of end effector functions. The surgical instrument system
also comprises a second handle comprising a second number of
controls. The surgical instrument system also comprises a shaft
assembly attachable to the first handle and the second handle,
wherein the shaft assembly is attachable to the first handle in a
first orientation, and wherein the shaft assembly is attachable to
the second handle in a second orientation. The surgical instrument
system also comprises an end effector attachable to the shaft
assembly.
Example 71
[0489] The surgical instrument system of Example 70, wherein the
first number of controls is different than the second number of
controls.
Example 72
[0490] The surgical instrument system of Examples 70 or 71, wherein
the first orientation is different than the second orientation.
Example 73
[0491] The surgical instrument system of Examples 70, 71, or 72,
wherein the first orientation prevents the surgical instrument from
performing at least one function of the end effector.
Example 74
[0492] The surgical instrument system of Examples 70, 71, 72, or
73, wherein the second orientation prevents the surgical instrument
from performing at least one function of the end effector.
Example 75
[0493] A surgical instrument system comprising a surgical
instrument configured to perform at least three functions of an end
effector, a first motor, a second motor, and a third motor. The
surgical instrument system further comprises a first handle
comprising a first number of controls, wherein each control
corresponds to an end effector function, a second handle comprising
a second number of controls, and a third handle comprising a third
number of controls. The surgical instrument system also comprises a
shaft assembly attachable to each of the handles, wherein the shaft
assembly is attachable to each of the handles in a different
orientation, and wherein the surgical instrument system is
configured to perform a different end effector function in each
different orientation, and wherein certain end effector functions
are locked out based on which motor is engaged in each
orientation.
Example 76
[0494] A surgical instrument system, comprising a surgical
instrument configured to perform at least three functions of an end
effector. The surgical instrument system also comprises a first
handle comprising a first number of controls, wherein each control
corresponds to an end effector function, a second handle comprising
a second number of controls, and a third handle comprising a third
number of controls. The surgical instrument system also comprises a
shaft assembly attachable to each of the handles, wherein the shaft
assembly is attachable to each of the handles in a different
orientation, and wherein the surgical instrument system is
configured to perform a different end effector function in each
different orientation, and wherein certain end effector functions
are locked out based on which handle is attached to the end
effector.
Example 77
[0495] A surgical instrument system comprising a first shaft
assembly configured to perform a first function, a second function,
and a third function and a second shaft assembly configured to
perform the first function and the second function, but not the
third function. The surgical instrument system also comprises a
handle, wherein the first shaft assembly and the second shaft
assembly are selectively and separately attachable to the handle,
wherein the handle comprises a first electric motor configured to
drive the first function, a second electric motor configured to
drive the second function, a third electric motor configured to
drive the third function when the first shaft assembly is attached
to the handle, and a lockout configured to prevent the third
electric motor from being operated when the second shaft assembly
is attached to the handle.
Example 78
[0496] The surgical instrument system of Example 77, wherein the
first shaft assembly is attachable to the handle in a first
orientation and the second shaft assembly is attachable to the
handle in a second orientation, and wherein the first orientation
is different than the second orientation.
Example 79
[0497] A surgical instrument system comprising a first shaft
assembly configured to perform a first function, a second function,
and a third function, a second shaft assembly configured to perform
the first function and the second function, and a handle, wherein
the first shaft assembly and the second shaft assembly are
selectively, and separately, attachable to the handle. The handle
comprises a first control configured to control the first function,
a second control configured to control the second function, and a
third control configured to control the third function when the
first shaft assembly is attached to the handle, and locking means
for locking out the third control when the second shaft assembly is
attached to the handle.
Example 80
[0498] The surgical instrument system of Example 79, wherein the
handle further comprises a microprocessor comprising input gates
and output gates, wherein the first control, the second control,
and the third control are in signal communication with the
microprocessor via the input gates, and wherein the locking means
comprises deactivating the input gate associated with the third
control when the second shaft assembly is attached to the
handle.
Example 81
[0499] The surgical instrument system of Example 79, wherein the
handle further comprises a microprocessor comprising input gates
and output gates, wherein the shaft assembly is in signal
communication with the microprocessor via the output gates, and
wherein the locking means comprises deactivating the output gate
associated with the third function when the second shaft assembly
is attached to the handle.
Example 82
[0500] A surgical instrument system comprising a shaft assembly
configured to perform a first function, a second function, and a
third function. The surgical instrument system also comprises a
first handle comprising a first control for controlling the first
function, a second control for controlling the second function, and
a third control for controlling the third function when the shaft
assembly is operably coupled to the first handle. The surgical
instrument system also comprises a second handle comprising a first
control for controlling the first function, a second control for
controlling the second function, and a lockout for preventing the
shaft assembly from performing the third function when the shaft
assembly is operably coupled to the second handle.
Example 83
[0501] The surgical instrument system of Example 82, wherein the
shaft assembly is attachable to the first handle in a first
orientation and the handle in a second orientation, and wherein the
first orientation is different than the second orientation.
Example 84
[0502] The surgical instrument system of Examples 82 or 83, wherein
the shaft assembly comprises a longitudinal axis, an end effector,
and an articulation joint, wherein the end effector comprises a jaw
movable between an open position and a closed position, wherein the
first function comprises moving the jaw, wherein the second
function comprises articulating the end effector about the
articulation joint, and wherein the third function comprises
rotating the shaft assembly about the longitudinal axis.
Example 85
[0503] A surgical instrument system comprising a shaft assembly
configured to perform a first function, a second function, and a
third function. The surgical instrument system also comprises a
first handle comprising a first motor for driving the first
function, a second motor for driving the second function, and a
third motor for driving the third function when the shaft assembly
is operably coupled to the first handle. The surgical instrument
system also comprises a second handle comprising a first motor for
driving the first function, a second motor for driving the second
function, and a lockout for preventing the shaft assembly from
performing the third function when the shaft assembly is operably
coupled to the second handle.
Example 86
[0504] The surgical instrument system of Example 85, wherein the
shaft assembly is attachable to the first handle in a first
orientation and the second handle in a second orientation, and
wherein the first orientation is different than the second
orientation.
Example 87
[0505] The surgical instrument system of Examples 85 or 86, wherein
the shaft assembly comprises a longitudinal axis, an end effector,
and an articulation joint, wherein the end effector comprises a jaw
movable between an open position and a closed position, wherein the
first function comprises moving the jaw, wherein the second
function comprises articulating the end effector about the
articulation joint, and wherein the third function comprises
rotating the shaft assembly about the longitudinal axis.
Example 88
[0506] The surgical instrument system of Examples 85, 86, or 87,
wherein the shaft assembly comprises a first drive system for
performing the first function, a second drive system for performing
the second function, and a third drive system for performing the
third function, and wherein the lockout comprises a locking element
configured to engage the third drive and prevent the third drive
from driving the third function.
Example 89
[0507] A surgical instrument system comprising a shaft assembly, a
first handle, and a second handle. The shaft assembly is configured
to perform a first function, a second function, and a third
function and comprises a first drive configured to perform the
first function, a second drive configured to perform the second
function, a third drive configured to perform the third function,
and a lockout, wherein the lockout is selectively switchable
between an unlocked configuration and a locked configuration,
wherein the lockout prevents the shaft assembly from performing the
third function when the lockout is in the locked configuration, and
wherein the lockout permits the shaft assembly to perform the third
function when the lockout is in the unlocked configuration. The
first handle comprises a first motor for driving the first
function, a second motor for driving the second function, a third
motor for driving the third function when the shaft assembly is
operably coupled to the first handle, and a control system
configured to place the lockout in the unlocked configuration. The
second handle comprises a first motor for driving the first
function, a second motor for driving the second function, and a
control system configured to place the lockout in the locked
configuration.
Example 90
[0508] A surgical instrument system comprising a first handle
comprising a first gripping portion and a first shaft lock, and a
second handle comprising a second gripping portion and a second
shaft lock. The surgical instrument system also comprises a shaft
assembly selectively, and separately, attachable to the first
handle and the second handle, wherein the first shaft lock holds
the shaft assembly to the first handle in a first orientation when
the shaft assembly is attached to the first handle, wherein the
second shaft lock holds shaft assembly to the second handle in a
second orientation when the shaft assembly is attached to the
second handle, and wherein the first orientation is different than
the second orientation.
Example 91
[0509] The surgical instrument system of Example 90, wherein the
shaft assembly comprises a housing and an array of lock apertures
extending around the housing, and wherein the first shaft lock and
the second shaft lock engage the lock apertures.
Example 92
[0510] The surgical instrument system of Example 91, wherein the
first shaft lock comprises an arcuate ridge including a first end
and a second end, a first lock shoulder at the first end, wherein
the first lock shoulder is positionable in a lock aperture, and a
second lock shoulder at the second end, wherein the second lock
shoulder is positionable in a lock aperture.
Example 93
[0511] The surgical instrument system of Examples 91 or 92, wherein
the second shaft lock comprises an arcuate ridge including a first
end and a second end, a first lock shoulder at the first end,
wherein the first lock shoulder is positionable in a lock aperture,
and a second lock shoulder at the second end, wherein the second
lock shoulder is positionable in a lock aperture.
Example 94
[0512] A surgical instrument system comprising a shaft assembly
comprising three drive functions, a first handle, and a second
handle. The shaft assembly is selectively attachable to the first
handle, wherein the first handle comprises a drive system
configured to drive all three drive functions of the shaft assembly
when the shaft assembly is attached to the first handle. The shaft
assembly is selectively attachable to the second handle, wherein
the second handle comprises a drive system configured to drive less
than all three functions of the shaft assembly when the shaft
assembly is attached to the second handle.
Example 95
[0513] The surgical instrument system of Example 94, wherein the
shaft assembly comprises a first drive system configured to perform
a first drive function of the three drive functions, a second drive
system configured to perform a second drive function of the three
drive functions, and a third drive system configured to perform a
third drive function of the three drive functions.
Example 96
[0514] The surgical instrument system of Example 95, wherein the
second handle comprises a housing and a lock projection, and
wherein the lock projection is configured to engage the second
drive system to prevent the operation of the second drive system
when the shaft assembly is assembled to the second handle.
Example 97
[0515] The surgical instrument system of Example 96, wherein the
second handle comprises another lock projection, and wherein the
another lock projection is configured to engage the third drive
system to prevent the operation of the third drive system when the
shaft assembly is assembled to the second handle.
Example 98
[0516] The surgical instrument system of Examples 96 or 97, wherein
the lock projection extends from the housing.
Example 99
[0517] The surgical instrument system of Examples 96, 97, or 98,
wherein the lock projection is integrally formed with the
housing.
Example 100
[0518] The surgical instrument system of Examples 94, 95, 96, 97,
98, or 99, wherein the first handle comprises a pistol grip and the
second handle comprises a scissors grip.
Example 101
[0519] The surgical instrument system of Examples 94, 95, 96, 97,
98, or 99, wherein the first handle comprises a pistol grip and the
second handle comprises a pencil grip.
Example 102
[0520] The surgical instrument system of Examples 94, 95, 96, 97,
98, 99, 100, or 101, wherein the shaft assembly comprises a clip
applier.
Example 103
[0521] A surgical instrument system comprising a shaft assembly
comprising three drive functions requiring power above a power
threshold, a first handle, and a second handle. The shaft assembly
is selectively attachable to the first handle, wherein the first
handle comprises a drive system configured to drive all three drive
functions of the shaft assembly at or above the power threshold
when the shaft assembly is attached to the first handle. The shaft
assembly is selectively attachable to the second handle, wherein
the second handle comprises a drive system configured to drive less
than all three functions of the shaft assembly at or above the
power threshold when the shaft assembly is attached to the second
handle, and wherein the second handle is configured to disable the
drive functions receiving power below the power threshold.
Example 104
[0522] A surgical instrument system comprising a handle assembly.
The handle assembly comprises an actuation trigger comprising a
curved proximal portion and a curved cylinder surrounding the
curved proximal portion of the actuation trigger, wherein the
curved cylinder comprises at least one electroactive polymer. The
surgical instrument system also comprises a motor, a shaft attached
to the handle assembly, an end effector attached to a distal end of
the shaft, an actuation rod configured to transmit an actuation
force to the end effector, and a sensor system configured to detect
the magnitude of the actuation force, wherein the electroactive
polymer is responsive to the actuation force, and wherein the
electroactive polymer provides tactile feedback to a user of the
surgical instrument system by applying forces to the actuation
trigger.
Example 105
[0523] The surgical instrument system of Example 104, wherein the
forces applied to the actuation trigger by the electroactive
polymer are proportional to the actuation force.
Example 106
[0524] The surgical instrument system of Example 105, wherein the
forces applied to the actuation trigger by the electroactive
polymer are directly proportional to the actuation force.
Example 107
[0525] The surgical instrument system of Example 106, wherein the
forces applied to the actuation trigger by the electroactive
polymer are linearly proportional to the actuation force.
Example 108
[0526] The surgical instrument system of Example 106, wherein the
forces applied to the actuation trigger by the electroactive
polymer are non-linearly proportional to the actuation force.
Example 109
[0527] The surgical instrument system of Examples 104, 105, 106,
107, or 108, further comprising a power source and a control system
in communication with the sensor system, the curved cylinder, and
the power source, wherein the control system is configured to apply
a voltage potential to the curved cylinder in response to the
actuation force detected by the sensor system.
Example 110
[0528] The surgical instrument system of Example 109, wherein the
voltage potential is proportional to the actuation force.
Example 111
[0529] The surgical instrument system of Example 110, wherein the
voltage potential is linearly proportional to the actuation
force.
Example 112
[0530] The surgical instrument system of Examples 109, 110, or 111,
wherein the curved cylinder expands in proportion to the magnitude
of the voltage potential applied to the curved cylinder.
Example 113
[0531] The surgical instrument system of Examples 104, 105, 106,
107, 108, 109, 110, 111, or 112, wherein the handle comprises a
cavity comprising a sidewall, wherein the curved cylinder is
positioned in the cavity, and wherein the sidewall prevents the
expansion of the curved cylinder when a voltage potential is
applied to the curved cylinder such that a gripping force is
applied to the curved proximal portion.
Example 114
[0532] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector comprises a
crimping mechanism configured to apply a clip to the tissue of a
patient, and wherein the crimping mechanism is driven by the
actuation rod.
Example 115
[0533] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector is configured
to apply staples to the tissue of a patient, and wherein the
staples are pushed out of a staple cartridge by the actuation
rod.
Example 116
[0534] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector comprises a
needle configured to apply a suture to the tissue of a patient, and
wherein the needle is driven by the actuation rod.
Example 117
[0535] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector comprises jaws
configured to grasp tissue, and wherein the actuation rod closes
the jaws.
Example 118
[0536] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector comprises jaws
configured to dissect tissue, and wherein the actuation rod opens
the jaws.
Example 119
[0537] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector is configured
to ablate tissue with electrical energy.
Example 120
[0538] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector comprises at
least one electrode and is configured to apply RF energy to
tissue.
Example 121
[0539] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the handle comprises a
transducer, and wherein the end effector is configured to apply
vibrational energy to tissue.
Example 122
[0540] The surgical instrument of Examples 104, 105, 106, 107, 108,
109, 110, 111, 112, or 113, wherein the end effector comprises a
knife configured to cut tissue, and wherein the knife is pushed
distally by the actuation rod.
Example 123
[0541] A surgical instrument system comprising a handle assembly
wherein the handle assembly comprises an actuation trigger and a
cylinder surrounding a portion of the actuation trigger, wherein
the cylinder comprises at least one electroactive polymer. The
surgical instrument system also comprises a power source, a motor,
an actuation member configured to transmit an actuation force, a
sensor system configured to detect the magnitude of the actuation
force, and a control system in communication with the sensor system
and the cylinder, wherein the control system is configured to apply
a voltage potential from the power source to the cylinder in
response to the actuation force, and wherein the cylinder applies a
gripping force to the actuation trigger indicative of the magnitude
of the actuation force.
Example 124
[0542] A surgical instrument system comprising a handle assembly
wherein the handle assembly comprises an actuation trigger and an
electroactive polymer actuator. The surgical instrument system also
comprises a voltage source, an electric motor, an actuation member
configured to transmit an actuation force, a sensor system
configured to detect the magnitude of the actuation force, and a
control system in communication with the sensor system and the
electroactive polymer actuator, wherein the control system is
configured to apply a voltage potential from the voltage source to
the electroactive polymer actuator in response to the actuation
force, and wherein the electroactive polymer actuator applies a
gripping force to the actuation trigger which is proportional to
the magnitude of the actuation force.
Example 125
[0543] A surgical instrument system comprising a handle assembly
wherein the handle assembly comprises an actuation trigger and an
electroactive polymer actuator. The surgical instrument system also
comprises a power source, an electric motor configured to draw an
electrical current from the power source, an actuation member
operably coupled to the electric motor which is configured to
transmit an actuation force, a sensor system configured to detect
the magnitude of the electrical current, and a control system in
communication with the sensor system and the electroactive polymer
actuator, wherein the control system is configured to apply a
voltage potential to the electroactive polymer actuator in response
to the electrical current, and wherein the electroactive polymer
actuator applies a gripping force to the actuation trigger which is
proportional to the magnitude of the electrical current.
Example 126
[0544] A robotic surgical instrument system comprising a surgical
robot and a console configured to control the surgical robot. The
console comprises an actuation trigger and an electroactive polymer
actuator. The robotic surgical instrument system comprises a power
source, an electric motor configured to draw an electrical current
from the power source, an actuation member operably coupled to the
electric motor which is configured to transmit an actuation force,
a sensor system configured to detect the magnitude of the
electrical current, and a control system in communication with the
sensor system and the electroactive polymer actuator, wherein the
control system is configured to apply a voltage potential to the
electroactive polymer actuator in response to the electrical
current, and wherein the electroactive polymer actuator applies a
gripping force to the actuation trigger which is proportional to
the magnitude of the electrical current.
Example 127
[0545] A robotic surgical instrument system comprising a surgical
robot and a console configured to control the surgical robot. The
console comprises an actuation trigger and an electroactive polymer
actuator. The robotic surgical instrument system also comprises a
voltage source, an electric motor, an actuation member configured
to transmit an actuation force, a sensor system configured to
detect the magnitude of the actuation force, and a control system
in communication with the sensor system and the electroactive
polymer actuator, wherein the control system is configured to apply
a voltage potential from the voltage source to the electroactive
polymer actuator in response to the actuation force, and wherein
the electroactive polymer actuator applies a gripping force to the
actuation trigger which is proportional to the magnitude of the
actuation force.
Example 128
[0546] A surgical instrument system comprising a handle assembly
which comprises an actuation trigger and an electroactive polymer
actuator. The surgical instrument system also comprises a voltage
source, an electric motor, an actuation member configured to
transmit an actuation force, a sensor system configured to detect
the magnitude of the actuation force, and a control system in
communication with the sensor system and the electroactive polymer
actuator, wherein the control system is configured to apply a
voltage potential from the voltage source to the electroactive
polymer actuator in response to the actuation force, and wherein
the electroactive polymer actuator applies a friction force to the
actuation trigger which is proportional to the magnitude of the
actuation force.
Example 129
[0547] A surgical instrument system comprising a handle assembly
which comprises an actuation trigger and an electroactive polymer
actuator. The surgical instrument system also comprises a voltage
source, an electric motor, an actuation member configured to
transmit an actuation force, a sensor system configured to detect
the magnitude of the actuation force, and a control system in
communication with the sensor system and the electroactive polymer
actuator, wherein the control system is configured to apply a
voltage potential from the voltage source to the electroactive
polymer actuator in response to the actuation force, and wherein
the electroactive polymer actuator applies a resistance force to
the actuation trigger which is proportional to the magnitude of the
actuation force.
Example 130
[0548] A surgical instrument system comprising a handle assembly
which comprises an actuation trigger and an electroactive polymer
actuator. The surgical instrument system also comprises a power
source, an electric motor configured to draw an electrical current
from the power source, an actuation member operably coupled to the
electric motor which is configured to transmit an actuation force,
a sensor system configured to detect the magnitude of the
electrical current, and a control system in communication with the
sensor system and the electroactive polymer actuator, wherein the
control system is configured to apply a voltage potential to the
electroactive polymer actuator in response to the electrical
current, and wherein the electroactive polymer actuator applies a
resistance force to the actuation trigger which is proportional to
the magnitude of the electrical current.
Example 131
[0549] A surgical instrument system comprising a surgical
instrument and a housing which comprises a handle assembly, at
least one motor, and a drive shaft. The surgical instrument system
also comprises a shaft assembly configured to be attached to a
distal end of the housing, wherein the shaft assembly comprises a
control circuit and a locking mechanism, wherein the locking
mechanism prevents movement of the drive shaft if the shaft
assembly is not attached to the surgical instrument in an
orientation which enables operation of the surgical instrument, and
wherein the locking mechanism further comprises sensing means for
determining whether the locking mechanism is actively engaged and
an end effector attachable to a distal end of the shaft
assembly.
Example 132
[0550] The surgical instrument system of Example 131, wherein the
control circuit further comprises at least one safety feature.
Example 133
[0551] The surgical instrument system of Examples 131 or 132,
wherein the locking mechanism is configured to prevent the
actuation of the surgical instrument.
Example 134
[0552] The surgical instrument system of Examples 131, 132, or 133,
wherein the locking mechanism is configured to prevent activation
of the motor.
Example 135
[0553] The surgical instrument system of Examples 131, 132, 133, or
134, wherein the locking mechanism prevents movement of the shaft
assembly when the shaft assembly is not attached to the
housing.
Example 136
[0554] The surgical instrument system of Examples 131, 132, 133,
134, or 135, wherein the locking mechanism is configured to detect
whether the end effector is in a usable state.
Example 137
[0555] The surgical instrument system of Examples 131, 132, 133,
134, 135, or 136, wherein the sensing means is configured to enable
haptic feedback of the motor in order to alert a user of a state of
the surgical instrument.
Example 138
[0556] A surgical instrument comprising a housing which comprises a
handle assembly, at least one motor, and a drive shaft. The
surgical instrument also comprises a shaft assembly configured to
be attached to a distal end of the housing, wherein the shaft
assembly comprises a control circuit, and a locking mechanism,
wherein the locking mechanism prevents movement of the drive shaft
if the shaft assembly is not attached to the surgical instrument in
an orientation which enables operation of the surgical instrument.
The surgical instrument also comprises an end effector attachable
to a distal end of the shaft assembly.
Example 139
[0557] The surgical instrument of Example 138, wherein the control
circuit further comprises at least one safety feature.
Example 140
[0558] The surgical instrument of Examples 138 or 139, wherein the
locking mechanism is configured to prevent the actuation of the
surgical instrument.
Example 141
[0559] The surgical instrument of Examples 138, 139, or 140,
wherein the locking mechanism is configured to prevent activation
of the motor.
Example 142
[0560] The surgical instrument of Examples 138, 139, 140, or 141,
wherein the locking mechanism prevents movement of the shaft
assembly when the shaft assembly is not attached to the
housing.
Example 143
[0561] The surgical instrument of Examples 138, 139, 140, 141, or
142, wherein the locking mechanism is configured to detect whether
the end effector is in a usable state.
Example 144
[0562] The surgical instrument of Examples 138, 139, 140, 141, 142,
or 143, wherein the sensing means is configured to enable haptic
feedback of the motor in order to alert a user of a state of the
surgical instrument.
Example 145
[0563] A surgical assembly comprising a surgical instrument and a
housing which comprises a handle, at least one motor, and a drive
shaft assembly. The surgical assembly also comprises a shaft
assembly configured to be attached to a distal end of the housing,
wherein the shaft assembly comprises a control circuit and a
locking mechanism, wherein the locking mechanism prevents movement
of the drive shaft if the shaft assembly is not attached to the
surgical instrument in an orientation which enables operation of
the surgical instrument and wherein the locking mechanism further
comprises an electrical sensor for determining whether the locking
mechanism is actively engaged within the surgical instrument. The
surgical assembly also comprises an end effector attachable to a
distal end of the shaft assembly.
Example 146
[0564] The surgical assembly of Example 145, wherein the control
circuit further comprises at least one safety feature.
Example 147
[0565] The surgical assembly of Examples 145 or 146, wherein the
locking mechanism is configured to prevent the actuation of the
surgical instrument.
Example 148
[0566] The surgical assembly of Examples 145, 146, or 147, wherein
the locking mechanism is configured to prevent activation of the at
least one motor.
Example 149
[0567] The surgical assembly of Examples 145, 146, 147, or 148,
wherein the locking mechanism prevents movement of the shaft
assembly when the shaft assembly is not attached to the
housing.
Example 150
[0568] The surgical assembly of Examples 145, 146, 147, 148, or
149, wherein the locking mechanism is configured to detect whether
the end effector is in a usable state.
Example 151
[0569] The surgical assembly of Examples 145, 146, 147, 148, 149,
or 150, wherein the electrical sensor is configured to enable
haptic feedback of the motor in order to alert a user of a state of
the surgical instrument.
Example 152
[0570] A surgical instrument configured to apply clips to the
tissue of a patient, comprising an end effector which comprises a
replaceable clip cartridge comprising a plurality of clips
removably stored therein, an actuator configured to deploy the
clips, and a lockout configurable in a locked configuration and an
unlocked configuration, wherein the lockout is in the locked
configuration when the replaceable clip cartridge is not in the end
effector, wherein the lockout prevents the actuator from being
actuated when the lockout is in the locked configuration, wherein
the lockout is in the unlocked configuration when the replaceable
clip cartridge is positioned in the end effector, and wherein the
lockout permits the actuator to deploy the clips when the lockout
is in the unlocked configuration. The surgical instrument also
comprises a handle, an electric motor configured to drive the
actuator, a control circuit configured to control the electric
motor, and a sensing system configured to determine when the
lockout is in the locked configuration, wherein the sensing system
is in communication with the control circuit, and wherein the
control circuit prevents the actuation of the electric motor when
the sensing system determines that the lockout is in the locked
configuration.
Example 153
[0571] A surgical instrument configured to apply clips to the
tissue of a patient, comprising an end effector which comprises a
replaceable clip cartridge comprising a plurality of clips
removably stored therein, an actuator configured to deploy the
clips, a lockout configurable in a locked configuration and an
unlocked configuration, wherein the lockout is in the locked
configuration when the replaceable clip cartridge is not in the end
effector, wherein the lockout prevents the actuator from being
actuated when the lockout is in the locked configuration, wherein
the lockout is in the unlocked configuration when the replaceable
clip cartridge is positioned in the end effector, and wherein the
lockout permits the actuator to deploy the clips when the lockout
is in the unlocked configuration. The surgical instrument also
comprises a handle, an electric motor configured to drive the
actuator, a control circuit configured to control the electric
motor, and a sensing system configured to determine when the
lockout is in the locked configuration, wherein the sensing system
is in communication with the control circuit, and wherein the
control circuit provides haptic feedback to the user of the
surgical instrument when the sensing system determines that the
lockout is in the locked configuration.
Example 154
[0572] A surgical instrument configured to apply clips to the
tissue of a patient comprising an end effector which comprises a
replaceable clip cartridge comprising a plurality of clips
removably stored therein, an actuator configured to deploy the
clips, and a lockout configurable in a locked configuration and an
unlocked configuration, wherein the lockout is in the locked
configuration when the replaceable clip cartridge has been
completely expended, wherein the lockout prevents the actuator from
being actuated when the lockout is in the locked configuration,
wherein the lockout is in the unlocked configuration when the
replaceable clip cartridge is positioned in the end effector and
has not been completely expended, and wherein the lockout permits
the actuator to deploy the clips when the lockout is in the
unlocked configuration. The surgical instrument also comprises a
handle, an electric motor configured to drive the actuator, a
control circuit configured to control the electric motor, and a
sensing system configured to determine when the lockout is in the
locked configuration, wherein the sensing system is in
communication with the control circuit, and wherein the control
circuit prevents the actuation of the electric motor when the
sensing system determines that the lockout is in the locked
configuration.
Example 155
[0573] A surgical instrument system configured to apply clips to
the tissue of a patient comprising a shaft assembly which comprises
a longitudinal axis, an end effector, an articulation joint
rotatably connecting the end effector to the shaft, a rotation
drive shaft configured to rotate the shaft about the longitudinal
axis, a clip firing drive shaft configured to deploy the clips, and
an articulation drive shaft configured to articulate the end
effector relative to the shaft. The end effector comprises a clip
cartridge comprising a plurality of clips removably stored therein
and an actuator configured to deploy the clips. The surgical
instrument system also comprises a first handle which comprises a
rotation drive system configured to drive the rotation drive shaft,
a clip firing drive system configured to drive the clip firing
drive shaft, and an articulation drive system configured to drive
the articulation drive shaft. The surgical instrument system also
comprises a second handle comprising a rotation drive lockout
configured to lock the rotation drive shaft, a clip firing drive
system configured to drive the clip firing drive shaft, and an
articulation drive lockout configured to lock the articulation
drive shaft.
Example 156
[0574] A surgical instrument configured to apply a suture to the
tissue of a patient, comprising an end effector which comprises a
replaceable suture cartridge comprising a suture removably stored
therein, an actuator configured to deploy the suture, and a lockout
configurable in a locked configuration and an unlocked
configuration, wherein the lockout is in the locked configuration
when the replaceable suture cartridge is not in the end effector,
wherein the lockout prevents the actuator from being actuated when
the lockout is in the locked configuration, wherein the lockout is
in the unlocked configuration when the replaceable suture cartridge
is positioned in the end effector, and wherein the lockout permits
the actuator to deploy the suture when the lockout is in the
unlocked configuration. The surgical instrument also comprises a
handle, an electric motor configured to drive the actuator, a
control circuit configured to control the electric motor, and a
sensing system configured to determine when the lockout is in the
locked configuration, wherein the sensing system is in
communication with the control circuit, and wherein the control
circuit prevents the actuation of the electric motor when the
sensing system determines that the lockout is in the locked
configuration.
Example 157
[0575] A surgical instrument configured to apply a suture to the
tissue of a patient comprising an end effector which comprises a
replaceable suture cartridge comprising a suture removably stored
therein, an actuator configured to deploy the suture, a lockout
configurable in a locked configuration and an unlocked
configuration, wherein the lockout is in the locked configuration
when the replaceable suture cartridge is not in the end effector,
wherein the lockout prevents the actuator from being actuated when
the lockout is in the locked configuration, wherein the lockout is
in the unlocked configuration when the replaceable suture cartridge
is positioned in the end effector, and wherein the lockout permits
the actuator to deploy the suture when the lockout is in the
unlocked configuration. The surgical instrument also comprises a
handle, an electric motor configured to drive the actuator, a
control circuit configured to control the electric motor, and a
sensing system configured to determine when the lockout is in the
locked configuration, wherein the sensing system is in
communication with the control circuit, and wherein the control
circuit provides haptic feedback to the user of the surgical
instrument when the sensing system determines that the lockout is
in the locked configuration.
Example 158
[0576] A surgical instrument configured to apply a suture to the
tissue of a patient comprising an end effector which comprises a
replaceable suture cartridge comprising a suture removably stored
therein, an actuator configured to deploy the suture, a lockout
configurable in a locked configuration and an unlocked
configuration, wherein the lockout is in the locked configuration
when the replaceable suture cartridge has been completely expended,
wherein the lockout prevents the actuator from being actuated when
the lockout is in the locked configuration, wherein the lockout is
in the unlocked configuration when the replaceable suture cartridge
is positioned in the end effector and has not been completely
expended, and wherein the lockout permits the actuator to deploy
the suture when the lockout is in the unlocked configuration. The
surgical instrument also comprises a handle, an electric motor
configured to drive the actuator, a control circuit configured to
control the electric motor, and a sensing system configured to
determine when the lockout is in the locked configuration, wherein
the sensing system is in communication with the control circuit,
and wherein the control circuit prevents the actuation of the
electric motor when the sensing system determines that the lockout
is in the locked configuration.
Example 159
[0577] A surgical instrument system configured to treat the tissue
of a patient, comprising a shaft assembly which comprises a
longitudinal axis, an end effector comprising a movable member and
an actuator configured to deploy the plurality of surgical clips,
an articulation joint rotatably connecting the end effector to the
shaft, a rotation drive shaft configured to rotate the shaft about
the longitudinal axis, a firing drive shaft configured to deploy
the movable member, and an articulation drive shaft configured to
articulate the end effector relative to the shaft. The surgical
instrument system also comprises a first handle comprising a
rotation drive system configured to drive the rotation drive shaft,
a firing drive system configured to drive the firing drive shaft,
and an articulation drive system configured to drive the
articulation drive shaft. The surgical instrument system also
comprises a second handle comprising a rotation drive lockout
configured to lock the rotation drive shaft and a firing drive
system configured to drive the firing drive shaft.
Example 160
[0578] A surgical instrument system configured to treat the tissue
of a patient comprising a shaft assembly which comprises a
longitudinal axis, an end effector comprising a movable member and
an actuator configured to deploy a plurality of clips, an
articulation joint rotatably connecting the end effector to the
shaft, a rotation drive shaft configured to rotate the shaft about
the longitudinal axis, a firing drive shaft configured to deploy
the movable member, and an articulation drive shaft configured to
articulate the end effector relative to the shaft. The surgical
instrument system also comprises a first handle comprising a
rotation drive system configured to drive the rotation drive shaft,
a firing drive system configured to drive the firing drive shaft,
and an articulation drive system configured to drive the
articulation drive shaft. The surgical instrument system also
comprises a second handle comprising an articulation drive lockout
configured to lock the articulation drive shaft and a firing drive
system configured to drive the firing drive shaft.
Example 161
[0579] A surgical instrument system configured to treat the tissue
of a patient comprising a shaft assembly configured to perform a
first function, a second function, and a third function wherein the
shaft assembly comprises a first drive shaft configured to perform
the first function, a second drive shaft configured to perform the
second function, and a third drive shaft configured to perform the
third function. The surgical instrument system also comprises a
first handle and a second handle. The first handle comprises a
first drive system configured to drive the first drive shaft, a
second drive system configured to drive the second drive shaft, and
a third drive system configured to drive the third drive shaft. The
second handle comprises a first drive lockout configured to lock
the first drive shaft and a second drive system configured to drive
the second drive shaft.
Example 162
[0580] The surgical instrument system of Example 161, wherein the
second handle comprises a drive lockout configured to lock the
third drive shaft.
Example 163
[0581] A surgical instrument system configured to treat the tissue
of a patient, comprising a shaft assembly which comprises a first
drive system configured to perform a first function, a second drive
system configured to perform a second function, a first lockout
configured to selectively engage the first drive system and prevent
the first drive system from performing the first function, and a
second lockout configured to selectively engage the second drive
system and prevent the second drive system from performing the
second function. The surgical instrument system also comprises a
first handle comprising a first operating system configured to
operate the first drive system and a second operating system
configured to operate the second drive system, wherein the first
lockout and the second lockout are disengaged when the shaft
assembly is assembled to the first handle. The surgical instrument
system also comprises a second handle comprising a first operating
system configured to operate the first drive system but not
comprising a second operating system configured to operate the
second drive system, wherein the first lockout is disengaged and
the second lockout is engaged when the shaft assembly is assembled
to the second handle.
Example 164
[0582] The surgical instrument system of Example 163, wherein the
first lockout and the second lockouts are in their engaged states
when the shaft assembly is not assembled to either the first handle
or the second handle.
Example 165
[0583] A surgical instrument system, comprising a handle comprising
a drive system including an electric motor and a shaft assembly
attachable to the handle, wherein the shaft assembly comprises a
drive shaft that is operably engaged with the drive system when the
shaft assembly is attached to the handle, wherein the drive system
is configured to drive the drive shaft when the shaft assembly is
in a usable condition. The surgical instrument system also
comprises a sensor system configured to evaluate the condition of
the shaft assembly and a control system in communication with the
drive system and the sensor system, wherein the control system is
configured to prevent the operation of the electric motor if the
shaft assembly is in an unusable condition.
Example 166
[0584] The surgical instrument system of Example 165, further
comprising a haptic feedback system in communication with the
control system, wherein the control system is configured to actuate
the haptic feedback system to provide haptic feedback to the user
of the surgical instrument system when the sensor system detects
that the shaft assembly is in an unusable condition.
Example 167
[0585] The surgical instrument system of Examples 165 or 166,
wherein the handle further comprises a second drive system, wherein
the shaft assembly further comprises a second drive shaft operably
engageable with the second drive system when the shaft assembly is
attached to the handle, and wherein the control system is
configured to use the second drive system when the sensor system
detects that the shaft assembly is in an unusable condition.
Example 168
[0586] A surgical instrument system comprising a handle which
comprises a housing, a handle electrical connector, a drive system
including an electric motor, and a power source. The surgical
instrument system also comprises a shaft assembly operably
attachable to the handle, wherein the shaft assembly comprises a
connector attachable to the housing when the shaft assembly is
attached to the handle, a drive shaft engageable with the drive
system when the shaft assembly is attached to the handle, a shaft
electrical connector configured to be electrically coupled with the
handle electrical connector when the shaft assembly is attached to
the handle, and a shaft control system in communication with the
shaft electrical connector, wherein the shaft control system is
configured to receive power from the power source through the shaft
electrical connector. The surgical instrument system also comprises
a lockout in communication with the shaft control system, wherein
the lockout comprises a solenoid, a lock element movable between an
unlocked position, a hold position, and a locked position, a catch
configured to releasably hold the lock element in the unlocked
position, wherein the solenoid is configured to release the catch
and allow the lock element to be moved into the hold position when
the shaft control system receives power from the power source, and
a biasing member configured to move the lock element into the hold
position when the catch releases the lock element and while the
shaft assembly is attached to the handle, wherein the biasing
member is configured to move the lock element into the locked
position once the shaft assembly is detached from the handle, and
wherein the lock element prevents the shaft assembly from being
re-attached to the handle once the lock element is in the locked
position.
Example 169
[0587] The surgical instrument system of Example 168, wherein the
shaft assembly comprises an unreleasable catch configured to hold
the lock element in the locked position.
Example 170
[0588] A surgical instrument system comprising a handle and a shaft
assembly operably attachable to the handle. The handle comprises a
housing and a power source. The shaft assembly comprises a
connector attachable to the housing when the shaft assembly is
attached to the handle, a shaft control system configured to
receive power from the power source when the shaft assembly is
attached to the handle, and a lockout in communication with the
shaft control system. The lockout comprises a lock element movable
between an unlocked position, a hold position, and a locked
position, a catch configured to releasably hold the lock element in
the unlocked position, wherein the catch is configured to allow the
lock element to be moved into the hold position when the shaft
control system receives power from the power source, and a biasing
member configured to move the lock element into the hold position
when the catch releases the lock element and while the shaft
assembly is attached to the handle, wherein the biasing member is
configured to move the lock element into the locked position once
the shaft assembly is detached from the handle, and wherein the
lock element prevents the shaft assembly from being re-attached to
the handle once the lock element is in the locked position.
Example 171
[0589] The surgical instrument system of Example 170, wherein the
shaft assembly comprises an unreleasable catch configured to hold
the lock element in the locked position.
[0590] Although various devices have been described herein in
connection with certain embodiments, modifications and variations
to those embodiments may be implemented. 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 ore more
other embodiments without limitation. Also, where materials are
disclosed for certain components, other materials may be used.
Furthermore, according to various embodiments, a single component
may be replaced by multiple components, and multiple components may
be replaced by a single component, to perform a given function or
functions. The foregoing description and following claims are
intended to cover all such modification and variations.
[0591] The devices disclosed herein can be designed to be disposed
of after a single use, or they can be designed to be used multiple
times. In either case, however, a device can be reconditioned for
reuse after at least one use. Reconditioning can include any
combination of the steps including, but not limited to, the
disassembly of the device, followed by cleaning or replacement of
particular pieces of the device, and subsequent reassembly of the
device. In particular, a reconditioning facility and/or surgical
team can disassemble a device and, after cleaning and/or replacing
particular parts of the device, the device can be reassembled for
subsequent use. Those skilled in the art will appreciate that
reconditioning of a device can utilize a variety of techniques for
disassembly, cleaning/replacement, and reassembly. Use of such
techniques, and the resulting reconditioned device, are all within
the scope of the present application.
[0592] The devices disclosed 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, and/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 may also be sterilized using any other technique known in
the art, including but not limited to beta radiation, gamma
radiation, ethylene oxide, plasma peroxide, and/or steam.
[0593] While this invention has been described as having exemplary
designs, the present invention may be further modified within the
spirit and scope of the disclosure. This application is therefore
intended to cover any variations, uses, or adaptations of the
invention using its general principles.
[0594] Any patent, publication, or other disclosure material, in
whole or in part, that is said to be incorporated by reference
herein is incorporated herein only to the extent that the
incorporated materials do 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.
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