Adjusting motor control command signals to adapt system variations

Abstract

A surgical stapling system includes an anvil, a blade, a motor and gear assembly, a motor power source, and a motor controller. A method of controlling a motor includes receiving first and second data indicative of operation of the motor under first and second conditions, respectively, and adjusting a motor control signal based on a difference between the first and second data. Another method includes receiving initial manufacturing motor and gear assembly data from a manufacturer and operational data during initial use of the system, and adjusting a parameter of a control signal based on a difference between the manufacturing data and the operational data. Another method includes controlling a pulse width modulation (PWM) motor control signal, receiving data regarding an interaction between a blade and tissue gripped by an anvil, and adjusting a frequency of the PWM signal based on the data relating to the interaction.

Description

[0001] Cross - Reference to Related Applications

[0002] This patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 63 / 411,445, filed Sep. 29, 2022, entitled "METHOD FOR CONTROLLING SURGICAL SYSTEM DURING TISSUE TREATMENT MOTION", under 35 U.S.C. § 119(e). The entire disclosure of the U.S. provisional patent application is incorporated herein by reference. BACKGROUND OF THE INVENTION

[0003] The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments designed to staple and cut tissue, and staple cartridges used therewith. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The various features of the embodiments described herein, along with their advantages, may be understood in connection with the following drawings according to the following description:

[0005] Figure 1 A perspective view of an electrosurgical stapling system;

[0006] Figure 2 For Figure 1 A perspective view of an interchangeable surgical shaft assembly of the electrosurgical stapling system;

[0007] Figure 3 For Figure 1 An exploded assembly view of multiple parts of the handle assembly of the electrosurgical stapling system;

[0008] Figure 4 For Figure 2 An exploded assembly view of the interchangeable surgical shaft assembly;

[0009] Figure 5 For Figure 4 Another partial exploded assembly view of a portion of the interchangeable surgical shaft assembly;

[0010] Figure 6 A perspective view of a shaft assembly according to at least one embodiment;

[0011] Figure 7 For Figure 6 An exploded view of the distal end of the shaft assembly;

[0012] Figure 8 A perspective view of a surgical instrument assembly including a proximal control interface, a shaft assembly, and an end effector assembly;

[0013] Figure 9 ForFigure 8 Bottom perspective view of a surgical instrument assembly;

[0014] Figure 10 Perspective view of an example of a form of a robotic controller according to one aspect of the present disclosure;

[0015] Figure 11 Perspective view of an example of a form of a robotic surgical arm cart / manipulator of a robotic surgical system operably supporting multiple surgical tools according to one aspect of the present disclosure;

[0016] Figure 12 According to one aspect of the present disclosure Figure 11 Side view of the robotic surgical arm cart / manipulator depicted in

[0017] Figure 13 Block diagram of a surgical system for use with one or more surgical instruments, tools, and / or robotic systems according to one or more aspects of the present disclosure;

[0018] Figure 14 Block diagram of a surgical system for use with one or more surgical instruments, tools, and / or robotic systems according to one or more aspects of the present disclosure;

[0019] Figure 15 Block diagram of an example of a delta-sigma modulation (DSM)-based bitstream controller according to one aspect of the present disclosure;

[0020] Figure 16 Graph showing an irregular pulse width modulation (PWM) motor control signal according to one aspect of the present disclosure;

[0021] Figure 17 Flowchart of a method for controlling a motor in an electrosurgical suturing system by changing the shape of a motor control signal according to one aspect of the present disclosure;

[0022] Figure 18 Graph showing the response of motor speed over time to the application of a step function signal according to one aspect of the present disclosure;

[0023] Figure 19 Illustration of a DC brushed motor with unworn brushes according to one aspect of the present disclosure;

[0024] Figure 20 Illustration of a DC brushed motor with worn brushes according to one aspect of the present disclosure;

[0025] Figure 21 Flowchart of a method for characterizing a motor in an electrosurgical suturing system according to one aspect of the present disclosure;

[0026] Figure 22 A diagram showing a stepper motor and a torque curve according to an aspect of the present disclosure;

[0027] Figure 23 A flowchart of a method for controlling a stepper motor in an electrosurgical suturing system according to an aspect of the present disclosure;

[0028] Figure 24 A flowchart of a method for controlling a motor in an electrosurgical suturing system based on data received from multiple sensors of the operation of subsystem components according to an aspect of the present disclosure;

[0029] Figure 25 A flowchart of a method for adjusting a motor control signal based on motor operation data according to an aspect of the present disclosure;

[0030] Figure 26 A flowchart of a method for adjusting parameters of a motor control signal based on the difference between initial manufacturing data and initial usage data according to an aspect of the present disclosure; and

[0031] Figure 27 A flowchart of a method for adjusting the frequency of a pulse width modulation motor control signal according to an aspect of the present disclosure.

[0032] In several views, corresponding reference symbols indicate corresponding parts. The examples described herein illustrate various embodiments of the present invention in one form, and such examples should not be construed as limiting the scope of the present invention in any way. Detailed Description

[0033] Numerous specific details are set forth herein to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments described in the specification and shown in the 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 shown herein are non-limiting examples, and thus it can be recognized that the specific structural and functional details disclosed herein can be representative and illustrative. Variations and changes can be made to these embodiments without departing from the scope of the claims.

[0034] 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. Thus, a surgical system, device, or apparatus that "comprises", "has", "includes", or "contains" one or more elements has those one or more elements, but is not limited to having only those one or more elements. Similarly, an element of a system, device, or apparatus that "comprises", "has", "includes", or "contains" one or more features has those one or more features, but is not limited to having only those one or more features.

[0035] The terms "proximal" and "distal" are used herein relative to a clinician manipulating the handle portion of a 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 should also be understood that, for simplicity and clarity, spatial terms such as "vertical", "horizontal", "upper", and "lower" may be used herein in conjunction with the figures. However, surgical instruments are used in many orientations and positions, and these terms are not restrictive and / or absolute.

[0036] A variety of exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily understand that the various methods and devices disclosed herein can be used in a variety of surgical procedures and applications, including, for example, in combination with open surgery. Continuing to refer to this detailed description, the reader will further understand that the various instruments disclosed herein can be inserted into the body in any manner, such as through natural body cavities, through incisions or puncture holes formed in tissue, etc. The working portion or end effector portion of the instrument can be inserted directly into the patient's body or can be inserted through an access device having a working channel through which the end effector and elongate shaft of the surgical instrument can be advanced.

[0037] A surgical stapling system may include a shaft and an end effector extending from the shaft. The end effector includes a first jaw and a second jaw. The first jaw includes a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are contemplated in which the staple cartridge is not removable from the first jaw or is at least easily replaceable from the first jaw. The second jaw includes an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are contemplated in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further includes an articulation joint configured to permit rotation or articulation of the end effector relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are contemplated that do not include an articulation joint.

[0038] The staple cartridge includes a cartridge body. The cartridge body includes a proximal end, a distal end, and a platform extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of tissue to be sutured, and the anvil is positioned on a second side of the tissue. The anvil moves toward the staple cartridge to compress and clamp the tissue against the platform. Then, staples removably stored in the cartridge body can be deployed into the tissue. The cartridge body includes a staple cavity defined within the cartridge body, wherein the staples are removably stored in the staple cavity. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples are possible.

[0039] The staples are supported by staple drivers in the cartridge body. The drivers are movable between a first or non-firing position and a second or firing position to eject the staples from the staple cavities. The drivers are retained in the cartridge body by a retainer that extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body. The drivers are movable between their non-firing position and their firing position by a slider. The slider is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The slider includes a plurality of ramp surfaces configured to slide beneath the drivers and lift the drivers toward the anvil, and the staples are supported on the drivers.

[0040] In addition to the above, the slider can also be moved distally by a firing member. The firing member is configured to be able to contact the slider and push the slider toward the distal end. A longitudinal slot defined in the cartridge body is configured to be able to receive the firing member. The anvil also includes a slot configured to be able to receive the firing member. The firing member also includes a first cam that engages the first jaw and a second cam that engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance or tissue gap between the platform of the staple cartridge and the anvil. The firing member also includes a blade configured to be able to cut into the tissue captured between the staple cartridge and the anvil. It is desirable for the blade to be positioned at least partially close to the ramp surface such that the staple is ejected prior to the blade.

[0041] Figure 1 A surgical instrument 1010 is shown including an interchangeable shaft assembly 1200 operably coupled to a housing 1012. Figure 2 An interchangeable shaft assembly 1200 is shown detached from the housing 1012 or the handle 1014. As Figure 3 can be seen, the handle 1014 can include a pair of interconnectable handle housing segments 1016 and 1018 that can be interconnected by screws, snap features, adhesives, etc. In the illustrated arrangement, the handle housing segments 1016, 1018 cooperate to form a pistol grip portion 1019. Figure 1 and Figure 3A motor-driven surgical cutting and fastening instrument 1010 that is reusable or non-reusable is shown. In the illustrated embodiment, the instrument 1010 includes a proximal housing 1012 that includes a handle 1014 configured to be grasped, manipulated, and actuated by a clinician. The housing 1012 is configured for operable attachment to an interchangeable shaft assembly 1200 that has a surgical end effector 1300 operably coupled thereto, the surgical end effector being configured to perform one or more surgical tasks or procedures. Continuing to refer to this detailed description, it will be understood that the various forms of interchangeable shaft assemblies disclosed herein may also be effectively used in conjunction with robotically controlled surgical systems. Accordingly, the term "housing" may also encompass the housing or similar portion of a robotic system that houses or otherwise operably supports at least one drive system configured to generate and apply at least one control action that can be used to actuate the interchangeable shaft assemblies and their corresponding equivalents disclosed herein. Additionally, various components may be "housed" or contained within the housing, or various components may be "associated" with the housing. In such cases, the components may not be housed within the housing or directly supported by the housing. The term "frame" may refer to a portion of a hand-held surgical instrument. The term "frame" may also denote a portion of a robotically controlled surgical instrument and / or a portion of a robotic system that can be used to operably control the surgical instrument. For example, the interchangeable shaft assemblies disclosed herein may be used with the various robotic systems, instruments, components, and methods disclosed in U.S. Patent No. 9,072,535, entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS," which is incorporated herein by reference in its entirety.

[0042] Figure 1 The depicted front side housing 1012 is shown in combination with the interchangeable shaft assembly 1200 Figure 2 、 Figure 4 and Figure 5) The interchangeable shaft assembly includes an end effector 1300, which includes a surgical cutting and fastening device configured to operably support a surgical staple cartridge 1301 therein. The housing 1012 can be configured for use with an interchangeable shaft assembly that includes an end effector adapted to support staple cartridges of different sizes and types, and the interchangeable shaft assembly has different shaft lengths, sizes, types, etc. In addition, the housing 1012 can also be effectively used with a variety of other interchangeable shaft assemblies, including those configured to apply other actions and forms of energy (such as, for example, radio frequency (RF) energy, ultrasonic energy, and / or actions) to end effector arrangements suitable for use in conjunction with various surgical applications and procedures. In addition, the end effector, shaft assembly, handle, surgical instrument, and / or surgical instrument system can utilize any suitable fasteners that can be grasped and manipulated by a clinician. As will be discussed in further detail below, the handle 1014 operably supports a plurality of drive systems therein, which are configured to generate various control actions and apply these control actions to corresponding portions of the interchangeable shaft assembly operably attached thereto.

[0043] Now referring to Figure 3 , the handle 1014 may also include a frame 1020 that operably supports a plurality of drive systems. For example, the frame 1020 is capable of operably supporting a "first" or closure drive system, generally labeled 1030, which can be used to apply closing and opening actions to an interchangeable shaft assembly 1200 operably attached or coupled thereto. In at least one form, the closure drive system 1030 may include an actuator in the form of a closure trigger 1032 pivotally supported by the frame 1020. More specifically, as Figure 3 shown, the closure trigger 1032 is pivotally coupled to the handle 1014 via a pin 1033. Such an arrangement enables the closure trigger 1032 to be manipulated by a clinician such that when the clinician grasps the pistol grip portion 1019 of the handle 1014, the closure trigger 1032 can be easily pivoted from its starting or "unactuated" position to an "actuated" position, and more specifically, to a fully compressed or fully actuated position. The closure trigger 1032 can be biased to the unactuated position by a spring or other biasing arrangement (not shown). In various forms, the closure drive system 1030 also includes a closure link assembly 1034 pivotally coupled to the closure trigger 1032. As Figure 3 can be seen, the closure link assembly 1034 may include a first closure link 1036 and a second closure link 1038 pivotally coupled to the closure trigger 1032 via a pin 1035. The second closure link 1038 may also be referred to herein as an "attachment member" and includes a lateral attachment pin 1037.

[0044] Still referring to Figure 3 it can be observed that the first closing connection member 1036 can have a locking wall or a locking end 1039 thereon, which is configured to be capable of cooperating with a closing release assembly 1060 pivotally coupled to the frame 1020. In at least one form, the closing release assembly 1060 can include a release button assembly 1062 having a locking pawl 1064 projecting distally formed thereon. The release button assembly 1062 can be pivoted counterclockwise by a release spring (not shown). When the clinician presses the closing trigger 1032 from its unactuated position towards the pistol grip portion 1019 of the handle 1014, the first closing connection member 1036 pivots upward to a point where the locking pawl 1064 drops into it to remain engaged with the locking wall 1039 on the first closing connection member 1036, thereby preventing the closing trigger 1032 from returning to the unactuated position. Thus, the closing release assembly 1060 is used to lock the closing trigger 1032 in the fully actuated position. When the clinician desires to unlock the closing trigger 1032 to allow it to be biased to the unactuated position, the clinician simply pivots the closing release button assembly 1062 such that the locking pawl 1064 moves out of engagement with the locking wall 1039 on the first closing connection member 1036. When the locking pawl 1064 has moved out of engagement with the first closing connection member 1036, the closing trigger 1032 can pivot back to the unactuated position. Other closing trigger locking arrangements and release arrangements can also be employed.

[0045] An arm 1061 can extend from the closing release button assembly 1062. A magnetic element 1063 (such as a permanent magnet) can be mounted to the arm 1061, for example. When the closing release button assembly 1062 rotates from its first position to its second position, the magnetic element 1063 can move towards the circuit board 1100. The circuit board 1100 can include at least one sensor configured to detect the movement of the magnetic element 1063. In at least one embodiment, for example, a "Hall effect" sensor (not shown) can be mounted to the bottom surface of the circuit board 1100. The Hall effect sensor can be configured to detect a change in the magnetic field surrounding the Hall effect sensor caused by the movement of the magnetic element 1063. The Hall effect sensor can communicate signals with, for example, a microcontroller, which can determine whether the closing release button assembly 1062 is in its first position associated with the unactuated position of the closing trigger 1032 and the open configuration of the end effector, its second position associated with the actuated position of the closing trigger 1032 and the closed configuration of the end effector, and / or any position between the first position and the second position.

[0046] In at least one form, the handle 1014 and the frame 1020 are operably supported by another drive system referred to herein as a firing drive system 1080, which is configured to be able to apply a firing action to a corresponding portion of an interchangeable shaft assembly attached thereto. The firing drive system 1080 may also be referred to herein as the "second drive system". The firing drive system 1080 may employ an electric motor 1082 positioned in the pistol grip portion 1019 of the handle 1014. In various forms, the motor 1082 may be a DC brushed drive motor having a maximum rotational speed of, for example, about 25,000 RPM. In other arrangements, the motor may include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor 1082 may be powered by a power source 1090, which in one form may include a removable power pack 1092. As Figure 3 visible, for example, the power pack 1092 may include a proximal housing portion 1094 configured for attachment to a distal housing portion 1096. The proximal housing portion 1094 and the distal housing portion 1096 are configured to be able to operably support a plurality of batteries 1098 therein. The batteries 1098 may each include, for example, a lithium ion (“LI”) or other suitable battery. The distal housing portion 1096 is configured for operably attaching in a removable manner to a handle circuit board 1100 that is also operably coupled to the motor 1082. The plurality of batteries 1098 may be connected in series and may serve as a power source for the surgical instrument 1010. Additionally, the power source 1090 may be replaceable and / or rechargeable.

[0047] As outlined above with respect to other various forms, the electric motor 1082 may include a rotatable shaft (not shown) operably interfacing with a gear reduction assembly 1084, which is mounted on a longitudinally movable drive member 1120 in meshing engagement with a set of drive teeth 1122 of a rack. In use, the voltage polarity provided by the power source 1090 may operate the electric motor 1082 in a clockwise direction, where the voltage polarity applied to the electric motor by the battery may be reversed in order to operate the electric motor 1082 in a counterclockwise direction. When the electric motor 1082 rotates in one direction, the drive member 1120 will be axially driven in the distal direction “DD”. When the motor 1082 is driven in the opposite rotational direction, the drive member 1120 will be axially driven in the proximal direction “PD”. The handle 1014 may include a switch that may be configured to reverse the polarity applied to the electric motor 1082 by the power source 1090. As with other forms described herein, the handle 1014 may also include a sensor configured to detect the position of the drive member 1120 and / or the direction in which the drive member 1120 is moving.

[0048] Actuation of the motor 1082 can be controlled by a firing trigger 1130 pivotally supported on the handle 1014. The firing trigger 1130 can pivot between an unactuated position and an actuated position. The firing trigger 1130 can be biased to the unactuated position by a spring 1132 or other biasing arrangement such that when the clinician releases the firing trigger 1130, the firing trigger can be pivoted or otherwise returned to the unactuated position by the spring 1132 or the biasing arrangement. In at least one form, the firing trigger 1130 can be positioned “outside” the closure trigger 1032, as discussed above. In at least one form, the firing trigger safety button 1134 can be pivotally mounted to the closure trigger 1032 by a pin 1035. The safety button 1134 can be positioned between the firing trigger 1130 and the closure trigger 1032 and has a pivot arm 1136 projecting therefrom. When the closure trigger 1032 is in the unactuated position, the safety button 1134 is received within the handle 1014 where it may not be readily accessible to the clinician and cannot be moved between a safety position that prevents actuation of the firing trigger 1130 and a firing position where the firing trigger 1130 can be fired. When the clinician depresses the closure trigger 1032, the safety button 1134 and the firing trigger 1130 pivot downward and can then be manipulated by the clinician.

[0049] As described above, in at least one form, the longitudinally movable drive member 1120 has teeth 1122 formed thereon in a rack for meshing engagement with a corresponding drive gear 1086 of the gear reducer assembly 1084. At least one form also includes a manually actuable “emergency” assembly 1140 configured to enable a clinician to manually retract the longitudinally movable drive member 1120 in the event that the motor 1082 becomes inoperative. The emergency assembly 1140 can include a lever or emergency handle assembly 1142 configured to be manually pivoted into ratchet engagement with teeth 1124 also provided in the drive member 1120. Thus, the clinician can manually retract the drive member 1120 by using the emergency handle assembly 1142 to cause the drive member 1120 to move in a ratcheting motion in the proximal direction “PD”. U.S. Patent No. 8,608,045, entitled “POWERED SURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRING SYSTEM”, discloses emergency arrangements and other components, arrangements, and systems that can also be used with the various instruments disclosed herein. U.S. Patent No. 8,608,045 is hereby incorporated by reference in its entirety.

[0050] Now turning to Figure 2 andFigure 5 , the interchangeable shaft assembly 1200 includes a surgical end effector 1300 that includes an elongate channel 1310 configured to operably support a staple cartridge 1301 therein. The end effector 1300 may further include an anvil 2000 pivotally supported relative to the elongate channel 1310. The interchangeable shaft assembly 1200 may further include an articulation joint 3020 and an articulation lock 2140 that may be configured to releasably hold the end effector 1300 in a desired position relative to the shaft axis SA. Examples of various features of at least one form of the end effector 1300, the articulation joint 3020, and the articulation lock can be seen in U.S. Patent Application Serial No. 13 / 803,086, filed Mar. 14, 2013, entitled “ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK” (now U.S. Patent Application Publication 2014 / 0263541). The complete disclosure of U.S. Patent Application Serial No. 13 / 803,086, filed Mar. 14, 2013, entitled “ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK” (now U.S. Patent Application Publication 2014 / 0263541) is hereby incorporated by reference herein. As Figure 4 seen, the interchangeable shaft assembly 1200 may further include a proximal housing or nozzle 1201 consisting of nozzle portions 1202 and 1203.

[0051] The interchangeable shaft assembly 1200 may further include a closure system or closure member assembly 3000 that may be used to close and / or open the anvil 2000 of the end effector 1300. The shaft assembly 1200 may include a ridge 1210 configured to: first, slidably support a firing member therein; and second, slidably support a closure member assembly 3000 extending around the ridge 1210. As Figure 5As can be seen, the distal end 1212 of the ridge 1210 terminates at an upper lug mounting feature 1270 and a lower lug mounting feature 1280. The upper lug mounting feature 1270 has a lug slot 1272 formed therein, and the lug slot is adapted to receive a support upper mounting connector 1274 therein. Similarly, the lower lug mounting feature 1280 has a lug slot 1282 formed therein, and the lug slot is adapted to receive a support lower mounting connector 1284 therein. The upper mounting connector 1274 includes a pivot bearing socket 1276, and the pivot bearing socket is adapted to rotatably receive a pivot pin 1292 therein. The pivot pin is formed on a channel cover or anvil holder 1290 attached to the proximal end portion 1312 of the elongated channel 1310. The lower mounting connector 1284 includes a lower pivot pin 1286, and the lower pivot pin is adapted to be received in a pivot hole 1314 formed in the proximal end portion 1312 of the elongated channel 1310. See Figure 5 . The lower pivot pin 1286 is vertically aligned with the pivot bearing socket 1276 to define a joint movement axis AA, about which the surgical end effector 1300 can articulate relative to the shaft axis SA. See Figure 2 .

[0052] In the illustrated example, the surgical end effector 1300 can be selectively articulated about the joint movement axis AA by the joint movement system 2100. In one form, the joint movement system 2100 includes a proximal joint movement driver 2102 that is pivotally coupled to a joint movement link 2120. As Figure 5As can be seen most specifically, a biasing attachment lug 2114 is formed on the distal end 2110 of the proximal articulation drive 2102. A pivot hole 2116 is formed in the biasing attachment lug 2114 and is configured to pivotally receive therein a proximal connector pin 2124 formed on the proximal end 2122 of the articulation link 2120. The distal end 2126 of the articulation link 2120 includes a pivot hole 2128 that is configured to pivotally receive therein a channel pin 1317 formed on the proximal end portion 1312 of the elongate channel 1310. Thus, axial movement of the proximal articulation drive 2102 will thereby impart articulation to the elongate channel 1310, causing the surgical end effector 1300 to articulate relative to the spine 1210 about the articulation axis AA. More details regarding the construction and operation of the articulation system 2100 can be seen in various references incorporated herein by reference, including U.S. Patent Application Serial No. 15 / 635,631, filed June 28, 2017, entitled “SURGICAL INSTRUMENT WITH AXIALLY - MOVABLE CLOSURE MEMBER” (now U.S. Patent Application Publication 2019 / 0000464), the entire disclosure of which is incorporated herein by reference. In various cases, when the proximal articulation drive 2102 is not moving in the proximal or distal direction, the proximal articulation drive 2102 can be held in place by the articulation lock 2140. Additional details regarding examples of the articulation lock 2140 can be seen in U.S. Patent Application Serial No. 15 / 635,631 (now U.S. Patent Application Publication 2019 / 0000464) and other references incorporated herein by reference.

[0053] In various cases, the spine 1210 can include a proximal end 1211 that is rotatably supported in the base 1240. In one arrangement, for example, the proximal end 1211 of the spine 1210 has threads 1214 formed thereon for threaded attachment to a spine bearing 1216 that is configured to be supported within the base 1240. See Figure 4 . This arrangement facilitates the rotatable attachment of the spine 1210 to the base 1240 such that the spine 1210 can be selectively rotated relative to the base 1240 about the axis SA.

[0054] Primarily see Figure 4 , the interchangeable shaft assembly 1200 includes a closure shuttle 1250 that is slidably supported within the base 1240 such that the closure shuttle is axially movable relative to the base. The closure shuttle 1250 includes a pair of proximally projecting hooks 1252 configured for attachment to an attachment pin 1037 ( Figure 3) The attachment pin is attached to the second closing connector 1038, as will be discussed in further detail below. In at least one example, the closing member assembly 3000 includes a proximal closing member segment 3010 having a proximal end 3012 that is coupled to the closing shuttle 1250 for rotation relative to the closing shuttle. For example, a U-shaped connector 1263 is inserted into an annular slot 3014 in the proximal end 3012 of the proximal closing member segment 3010 and retained within a vertical slot 1253 in the closing shuttle 1250. Such an arrangement is used to attach the proximal closing member segment 3010 to the closing shuttle 1250 for axial travel with the closing shuttle, while allowing the proximal closing member segment 3010 to rotate about the axis SA relative to the closing shuttle 1250. A closing spring 1268 is journaled on the proximal closing member segment 3010 and is used to bias the proximal closing member segment 3010 in the proximal direction "PD", which can be used to pivot the closing trigger 1032 to the unactuated position when the shaft assembly is operatively coupled to the handle 1014.

[0055] In at least one form, the interchangeable shaft assembly 1200 may also include a gimbal joint 3020. However, other interchangeable shaft assemblies may not be capable of gimbal movement. As Figure 5 can be seen, for example, a distal closing member or a distal closing tube segment 3030 is coupled to the distal end of the proximal closing member segment 3010. The gimbal joint 3020 includes a double pivot closing sleeve assembly 3022. According to various forms, the double pivot closing sleeve assembly 3022 includes an end effector closing tube 3050 having an upper shank 3052 and a lower shank 3054 that project distally. The upper double pivot connector 3056 includes a distally projecting distal pivot pin and a proximally projecting proximal pivot pin that engage an upper distal pin hole in the proximally projecting upper shank 3052 on the distal closing tube segment 3030 and an upper proximal pin hole in the distally projecting upper shank 3032, respectively. The lower double pivot connector 3058 includes a distally projecting distal pivot pin and a proximally projecting proximal pivot pin that engage a lower distal pin hole in the proximally projecting lower shank 3054 and a lower proximal pin hole in the distally projecting lower shank 3034, respectively. See Figure 4 and Figure 5 . As will be discussed in further detail below, the closing member assembly 3000 translates distally (direction "DD") to close the anvil 2000, for example, in response to actuation of the closing trigger 1032. The anvil 2000 is opened by translating the closing member assembly 3000 proximally, which causes the end effector closing sleeve to interact with the anvil 2000 and pivot it to the open position.

[0056] As described above, the interchangeable shaft assembly 1200 also includes a firing member 1900 that is supported for axial travel within the ridge 1210. The firing member 1900 includes an intermediate firing shaft portion 1222 that is configured for attachment to a distal cutting portion or knife bar 1910. The intermediate firing shaft portion 1222 may include a longitudinal slot 1223 in its distal end that is configured to receive a tab 1912 on the proximal end of the distal knife bar 1910. The longitudinal slot 1223 and the proximal end tab 1912 may be sized and configured to allow relative movement between the longitudinal slot and the proximal end tab and may include a slip joint 1914. The slip joint 1914 may allow movement of the intermediate firing shaft portion 1222 of the firing member 1900 to articulate the end effector 1300 without movement or at least substantially without movement of the knife bar 1910. Once the end effector 1300 has been properly oriented, the intermediate firing shaft portion 1222 may be advanced distally until the proximal sidewall of the longitudinal slot 1223 contacts the tab 1912 to advance the knife bar 1910 and fire a staple cartridge 1301 positioned within the channel 1310. The knife bar 1910 includes a knife portion 1920 and includes an upper anvil engaging tab 1924 and a lower channel engaging tab 1926, and the knife portion includes a blade or tissue cutting edge 1922. Various firing member configurations and operations are disclosed in various other references incorporated herein by reference.

[0057] Embodiments are also contemplated in which a shifter assembly may be used instead of the slip joint 1914. Details of such shifter assemblies and corresponding components, assemblies, and systems can be found in U.S. Patent Application No. 15 / 635,521, entitled "SURGICAL INSTRUMENT LOCKOUT ARRANGEMENT", the entire content of which is incorporated herein by reference.

[0058] As Figure 4As can be seen, the shaft assembly 1200 also includes a switching cylinder 1500 rotatably received on the proximal closure member segment 3010. The switching cylinder 1500 includes a hollow shaft segment 1502 having a shaft boss formed thereon for receiving a protruding actuation pin therein. In various cases, the actuation pin extends through a slot into a longitudinal slot provided in the locking sleeve to facilitate axial movement of the locking sleeve when the locking sleeve engages the joint motion driver. The rotary torsion spring 1420 is configured to engage a boss on the switching cylinder 1500 and a portion of the nozzle housing 1203 to apply a biasing force to the switching cylinder 1500. The switching cylinder 1500 may also include at least partially peripheral openings 1506 defined therein, which are configured to receive peripheral mounts extending from the nozzle portions 1202, 1203 and to allow relative rotation rather than relative translation between the switching cylinder 1500 and the nozzle 1201. The mounts also extend through an opening 3011 in the proximal closure member segment 3010 into a recess 1219 to be disposed in the ridge 1210. Rotation of the switching cylinder 1500 about the axis SA will ultimately cause rotation of the actuation pin and the locking sleeve between their engaged and disengaged positions. In one arrangement, rotation of the switching cylinder 1500 may be associated with axial advancement of the closure tube or closure member. Thus, in essence, actuation of the closure system can operably engage and disengage the joint motion drive system and the firing drive system in various ways, which are described in more detail in U.S. Patent Application Serial No. 13 / 803,086 (now U.S. Patent Application Publication 2014 / 0263541) entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK" and U.S. Patent 9,913,642 entitled "SURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM", the entire disclosures of which are hereby incorporated by reference herein. For example, when the closure tube is in its most proximal position corresponding to the "jaw open" position, the closure member segment 3010 will have positioned the switching cylinder 1500 to connect the joint motion system to the firing drive system. When the closure tube has moved to its distal position corresponding to the "jaw closed" position, the closure tube has rotated the switching cylinder 1500 to a position where the joint motion system is disconnected from the firing drive system.

[0059] Also as Figure 4As shown, the shaft assembly 1200 can include a slip ring assembly 1600 that can be configured, for example, to conduct electrical power to and / or from the end effector 1300 and / or to transmit signals to and / or receive signals from the end effector 1300. The slip ring assembly 1600 can include a proximal connector flange 1604 and a distal connector flange. The proximal connector flange is mounted to a base flange 1242 extending from the base 1240, and the distal connector flange is positioned within a slot defined in the shaft housing. The proximal connector flange 1604 can include a first face, and the distal connector flange can include a second face that is positioned adjacent to and movable relative to the first face. The distal connector flange can rotate relative to the proximal connector flange 1604 about the shaft axis SA. The proximal connector flange 1604 can include a plurality of concentric or at least substantially concentric conductors defined in its first face. Connectors can be mounted on the proximal side faces of the connector flanges and can have a plurality of contacts, where each contact corresponds to and is in electrical contact with one of the conductors. Such an arrangement allows relative rotation between the two flanges while maintaining electrical contact between the proximal connector flange 1604 and the distal connector flange. For example, the proximal connector flange 1604 can include an electrical connector 1606 that can enable signal communication between the conductors and a shaft circuit board 1610 mounted to the shaft base 1240. In at least one case, a wire harness including a plurality of conductors can extend between the electrical connector 1606 and the shaft circuit board 1610. The electrical connector 1606 can extend proximally through a connector opening 1243 defined in the base flange 1242. See Figure 4 . More details regarding the slip ring assembly 1600 can be found, for example, in U.S. Patent Application Serial No. 13 / 803,086 (now U.S. Patent Application Publication 2014 / 0263541) entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK", U.S. Patent Application Serial No. 13 / 800,067 (now U.S. Patent Application Publication 2014 / 0263552) entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM" filed on March 13, 2013, and U.S. Patent 9,345,481 entitled "STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM". U.S. Patent Application Serial No. 13 / 803,086 (now U.S. Patent Application Publication 2014 / 0263541), U.S. Patent Application Serial No. 13 / 800,067 (now U.S. Patent Application Publication 2014 / 0263552), and U.S. Patent 9,345,481 are hereby incorporated by reference in their entireties herein.

[0060] As discussed above, the shaft assembly 1200 can include a proximal portion and a distal portion. The proximal portion can be fixedly mounted to the handle 1014, and the distal portion is capable of rotating about a longitudinal axis. The rotatable distal shaft portion can rotate relative to the proximal portion about the slip ring assembly 1600 as discussed above. The distal connector flange of the slip ring assembly 1600 can be positioned within the rotatable distal shaft portion. Moreover, in addition to the above, the switching cylinder 1500 can also be positioned within the rotatable distal shaft portion. When the rotatable distal shaft portion rotates, the distal connector flange and the switching cylinder 1500 can rotate synchronously with each other. Additionally, the switching cylinder 1500 can rotate between a first position and a second position relative to the distal connector flange. When the switching cylinder 1500 is in its first position, the articulation drive system can be operatively disengaged from the firing drive system, and thus, the operation of the firing drive system can not cause the end effector 1300 of the shaft assembly 1200 to articulate. When the switching cylinder 1500 is in its second position, the articulation drive system can be operatively engaged with the firing drive system, and thus, the operation of the firing drive system can cause the end effector 1300 of the shaft assembly 1200 to articulate. When the switching cylinder 1500 moves between its first position and its second position, the switching cylinder 1500 moves relative to the distal connector flange. In various cases, the shaft assembly 1200 can include at least one sensor configured to detect the position of the switching cylinder 1500.

[0061] Referring again to Figure 4 , the base 1240 includes at least one, and preferably two, tapered attachment portions 1244 formed thereon, which tapered attachment portions are adapted to be received within corresponding dovetail slots 1702 formed within the distal attachment flange portion 1700 of the frame 1020. Refer to Figure 3 . Each dovetail slot 1702 can be tapered, or in other words, can be slightly V-shaped, so as to receive the attachment portion 1244 therein in a seating manner. As further visible in Figure 4 , the shaft attachment lug 1226 is formed on the proximal end of the intermediate firing shaft portion 1222. As will be discussed in further detail below, when the interchangeable shaft assembly 1200 is coupled to the handle 1014, the shaft attachment lug 1226 is received within a firing shaft attachment bracket 1126 formed in the distal end 1125 of the longitudinal drive member 1120. Refer to Figure 3 .

[0062] Various shaft assembly embodiments employ a latch system 1710 to removably couple the shaft assembly 1200 to the housing 1012 and more particularly to the frame 1020. As Figure 4As can be seen, for example, in at least one form, the latch system 1710 includes a locking member or locking yoke 1712 movably coupled to the base 1240. In an illustrated embodiment, for example, the locking yoke 1712 is U-shaped and has two spaced-apart and downwardly extending legs 1714. Each of the legs 1714 has a pivot lug 1715 formed thereon, and these pivot lugs are adapted to be received in corresponding holes 1245 formed in the base 1240. Such an arrangement facilitates pivotally attaching the locking yoke 1712 to the base 1240. The locking yoke 1712 may include two proximally projecting locking lugs 1716, which are configured to releasably engage corresponding locking ratchets or grooves 1704 in the distal attachment flange portion 1700 of the frame 1020. See Figure 3 . In various forms, the locking yoke 1712 is biased in the proximal direction by a spring or biasing member (not shown). Actuation of the locking yoke 1712 can be achieved by a latch button 1722, which is slidably mounted on a latch actuator assembly 1720 mounted to the base 1240. The latch button 1722 can be biased in the proximal direction relative to the locking yoke 1712. As will be discussed in further detail below, the locking yoke 1712 can be moved to an unlocked position by biasing the latch button in the distal direction, which also pivots the locking yoke 1712 out of engagement with the distal attachment flange portion 1700 of the frame 1020. When the locking yoke 1712 is "in engagement" with the distal attachment flange portion 1700 of the frame 1020, the locking lugs 1716 remain seated within the corresponding locking ratchets or grooves 1704 in the distal attachment flange portion 1700.

[0063] When using an interchangeable shaft assembly that includes an end effector of the type described herein adapted to cut and fasten tissue, as well as other types of end effectors, it may be advantageous to prevent the interchangeable shaft assembly from inadvertently disengaging from the housing during actuation of the end effector. For example, in use, a clinician may actuate the closure trigger 1032 to grasp the target tissue and manipulate it into a desired position. Once the target tissue is positioned within the end effector 1300 in a desired orientation, the clinician can fully actuate the closure trigger 1032 to close the anvil 2000 and clamp the target tissue in place for cutting and suturing. In this case, the first drive system 1030 has been fully actuated. After the target tissue has been clamped in the end effector 1300, it may be advantageous to prevent the shaft assembly 1200 from inadvertently disengaging from the housing 1012. One form of the latch system 1710 is configured to prevent such inadvertent disengagement.

[0064] As Figure 4It can be seen most specifically that the locking yoke 1712 includes at least one, and preferably two, locking hooks 1718 that are adapted to contact corresponding locking lug portions 1256 formed on the closure shuttle 1250. When the closure shuttle 1250 is in the unactuated position (i.e., the first drive system 1030 is unactuated and the anvil 2000 is open), the locking yoke 1712 is pivotable in the distal direction to unlock the interchangeable shaft assembly 1200 from the housing 1012. In this position, the locking hooks 1718 do not contact the locking lug portions 1256 on the closure shuttle 1250. However, when the closure shuttle 1250 is moved to the actuated position (i.e., the first drive system 1030 is actuated and the anvil 2000 is in the closed position), the locking yoke 1712 is impeded from pivoting to the unlocked position. In other words, if a clinician attempts to pivot the locking yoke 1712 to the unlocked position, or for example, the locking yoke 1712 is inadvertently bumped or contacted in a manner that would otherwise cause it to pivot distally, the locking hooks 1718 on the locking yoke 1712 will contact the locking lug portions 1256 on the closure shuttle 1250 and prevent the locking yoke 1712 from moving to the unlocked position.

[0065] The attachment of the interchangeable shaft assembly 1200 to the handle 1014 will now be described. To begin the coupling process, a clinician may position the base 1240 of the interchangeable shaft assembly 1200 above or near the distal attachment flange portion 1700 of the frame 1020 such that the tapered attachment portion 1244 formed on the base 1240 is aligned with the dovetail slot 1702 in the frame 1020. The clinician may then move the shaft assembly 1200 along an installation axis perpendicular to the shaft axis SA to seat the attachment portion 1244 into "operable engagement" with the corresponding dovetail receiving slot 1702. In doing so, the shaft attachment lug 1226 on the intermediate firing shaft portion 1222 will also seat in the bracket 1126 in the longitudinally movable drive member 1120, and a portion of the pin 1037 on the second closure link 1038 will seat in the corresponding hook 1252 in the closure shuttle 1250. As used herein, the term "operable engagement" in the context of two components means that the two components are sufficiently engaged with each other such that once an actuation action is applied to them, the components can perform their intended actions, functions, and / or procedures.

[0066] At least five systems of the interchangeable shaft assembly 1200 can be operably coupled with at least five corresponding systems of the handle 1014. The first system can include a frame system that couples and / or aligns the frame 1020 or spine 1210 of the shaft assembly 1200 with the frame 1020 of the handle 1014. Another system can include a closure drive system 1030 that can operably connect the closure trigger 1032 of the handle 1014 with the closure tube of the shaft assembly 1200. As outlined above, the closure shuttle 1250 of the shaft assembly 1200 can engage a pin 1037 on the second closure link 1038. Another system can include a firing drive system 1080 that can operably connect the firing trigger 1130 of the handle 1014 with the intermediate firing shaft portion 1222 of the shaft assembly 1200. As outlined above, the shaft attachment lug 1226 can be operably connected with a bracket 1126 of the longitudinal drive member 1120. Another system can include an electrical system that is capable of: sending a signal that the shaft assembly (such as the shaft assembly 1200) has been operably engaged with the handle 1014 to a controller (such as a microcontroller) in the handle 1014, and / or conducting power and / or communication signals between the shaft assembly 1200 and the handle 1014. For example, the shaft assembly 1200 can include an electrical connector 1810 operably mounted to a shaft circuit board 1610. The electrical connector 1810 is configured to mate and engage with a corresponding electrical connector 1800 on the control circuit board 1100. More details regarding the circuitry and control systems can be found in U.S. Patent Application Serial No. 13 / 803,086, now U.S. Patent Application Publication 2014 / 0263541, entitled "ARTICULATABLE SURGICAL INSTRUMENT COMPRISING AN ARTICULATION LOCK", and U.S. Patent Application Serial No. 14 / 226,142, now U.S. Patent 9,913,642, entitled "SURGICAL INSTRUMENT COMPRISING A SENSOR SYSTEM", the entire disclosures of which are hereby incorporated by reference herein. The fifth system can consist of a latch system for releasably locking the shaft assembly 1200 to the handle 1014.

[0067] In the illustrated example, anvil 2000 includes anvil body 2002 that terminates in anvil mounting portion 2010. Anvil mounting portion 2010 is movably or pivotally supported on elongate channel 1310 for selective pivotal travel relative to the elongate channel about a fixed anvil pivot axis PA that is transverse to shaft axis SA. In the illustrated arrangement, pivot members or anvil trunnions 2012 extend laterally out from each lateral side of anvil mounting portion 2010 to be received within corresponding trunnion brackets 1316 formed in upright walls 1315 of proximal end portion 1312 of elongate channel 1310. Anvil trunnions 2012 are pivotally held within their corresponding trunnion brackets 1316 by channel cover or anvil retainer 1290. Channel cover or anvil retainer 1290 includes a pair of attachment lugs that are configured to be retainingly received within corresponding lug grooves or notches formed in upright walls 1315 of proximal end portion 1312 of elongate channel 1310. See Figure 5 .

[0068] Still referring to Figure 5 , in at least one arrangement, distal closure member or end effector closure tube 3050 employs two axially offset proximal positive jaw opening features 3060 and distal positive jaw opening feature 3062. Positive jaw opening features 3060, 3062 are configured to interact with corresponding release regions and step portions formed on anvil mounting portion 2010, as described in greater detail in U.S. Patent Application Serial No. 15 / 635,631 (now U.S. Patent Application Publication 2019 / 0000464) entitled “SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSURE MEMBER”, the entire disclosure of which is incorporated herein by reference. Other jaw opening arrangements may be employed.

[0069] Figure 6 and Figure 7 Illustrated is shaft assembly 100. Shaft assembly 100 includes attachment portion 110, shaft 120 that extends distally from attachment portion 110, and end effector 130 that is attached to shaft 120. Shaft assembly 100 is configured to grasp, suture, and cut tissue. Attachment portion 110 is configured to be attached to, for example, a handle of a surgical instrument and / or an arm of a surgical robot.

[0070] See Figure 7 , shaft assembly 100 includes cooperating articulation levers 144, 145 that are configured to articulate end effector 130 relative to shaft 120 about articulation joint 160. Shaft assembly 100 also includes articulation lock lever 148, outer shaft tube 162, and ridge portion 123.

[0071] See Figure 7 , the firing assembly 100 includes a firing shaft 150, which includes a firing member 156 attached to the distal end of the firing shaft 150. The firing member 156 includes an upper cam flange configured to engage the anvil jaw 133 and a lower cam member configured to engage the cartridge jaw 132. The firing shaft 150 is configured to be advanced distally through a closing stroke to clamp the anvil jaw 133 relative to the cartridge jaw 132 using the cam member. The firing shaft 150 is further advanced through a firing stroke and is configured to advance the firing member 156 through the cartridge jaw 132 to deploy a staple from the cartridge jaw 132 and cut tissue during the firing stroke. More details of the shaft assembly 100 can be found in U.S. Patent Application No. 15 / 385,887, entitled "METHOD FOR ATTACHING ASHAFT ASSEMBLY TO A SURGICAL INSTRUMENT AND,ALTERNATIVELY,TO A SURGICALROBOT", the entire disclosure of which is incorporated herein by reference.

[0072] Figure 8 and Figure 9 depicts a surgical instrument assembly 200 configured to be used with a surgical robot. The surgical instrument assembly 200 is configured to suture and cut tissue, but the surgical instrument assembly 200 may be adapted to handle tissue in any suitable manner, such as, for example, by applying thermal, electrical, and / or vibrational energy to the tissue. The surgical instrument assembly 200 includes a proximal control interface 210 configured to be coupled to a robotic arm of a surgical robot and a shaft assembly 220 configured to be attached to the proximal control interface 210. The shaft assembly 220 includes an end effector 230 configured to grasp, cut, and suture tissue. The proximal control interface 210 includes a plurality of drive disks 211, each drive disk for actuating one or more functions of the surgical instrument assembly 200. Each drive disk 211 can be independently driven by one or more motors of the surgical robot and / or the robotic arm of the surgical robot and / or driven in cooperation with one or more other drive disks 211. More details regarding the surgical instrument assembly 200 can be found in U.S. Patent Application No. 15 / 847,297, entitled "SURGICALINSTRUMENTS WITH DUAL ARTICULATION DRIVERS", the entire disclosure of which is incorporated herein by reference.

[0073] The various embodiments disclosed herein can be employed, for example, in conjunction with Figures 10 to 12 a robotic system 300 of the type depicted in Figure 10 depicts that can be combined with Figure 11A type of robotic arm depicted in the main controller 301 used by the moving cart 310. The main controller 301 and the robotic arm moving cart 310, as well as their respective components and control systems, are collectively referred to herein as the robotic system 300. Examples of such systems and devices are disclosed in U.S. Patent No. 7,524,320 entitled "MECHANICAL ACTUATOR INTERFACE SYSTEM FOR ROBOTIC SURGICAL TOOLS" and U.S. Patent No. 9,072,535 entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS", the entire text of each of these patent applications being incorporated herein by reference. Accordingly, various details of such devices will not be described in detail herein, except as may be necessary to understand the various embodiments and forms of the present disclosure. As is well known, the main controller 301 generally includes a main controller (generally designated as 303 in Figure 10 which is grasped and manipulated in the air by the surgeon while the surgeon observes the surgery via the stereoscopic display 302. The main controller 301 generally includes manual input devices that preferably move in multiple degrees of freedom and typically also have an actuatable handle for actuating tools (e.g., for closing grasping jaws, applying electrical potential to electrodes, etc.).

[0074] As Figure 11As can be seen, in one form, the robotic arm cart 310 can be configured to be capable of actuating one or more surgical tools generally referred to as 330. Various robotic surgical systems and methods employing a master controller and robotic arm cart arrangement are disclosed in U.S. Patent No. 6,132,368, entitled "MULTI-COMPONENT TELEPRESENCE SYSTEM AND METHOD", the entire disclosure of which is incorporated herein by reference. In various forms, the robotic arm cart 310 includes a base 312, which in the illustrated embodiment can support surgical tools. In various forms, the surgical tools can be supported by a series of manually articulated links (generally referred to as device joints 314) and a robotic manipulator 316. In various embodiments, the link and joint arrangement can facilitate rotation of the surgical tool about a spatial point, as more fully described in U.S. Patent No. 5,817,084, entitled "REMOTE CENTER POSITIONING DEVICE WITH FLEXIBLE DRIVE", the entire disclosure of which is incorporated herein by reference. The parallelogram arrangement constrains the rotation to pivot about an axis 322a (sometimes referred to as the pitch axis). The connecting member that supports the parallelogram link is pivotally mounted to the device joint 314( Figure 11), such that the surgical tool also rotates about an axis 322b (sometimes referred to as the yaw axis). The pitch axis 322a and the yaw axis 322b intersect at a remote center 324, which is aligned along the elongate axis of the surgical tool. When supported by the manipulator 316, the surgical tool can have additional degrees of freedom of actuation, including a sliding motion of the surgical tool along the longitudinal axis "LT-LT". When the surgical tool slides relative to the manipulator 316 (arrow 322c) along the tool axis LT-LT, the remote center 324 remains fixed relative to the base 326 of the manipulator 316. Thus, the entire manipulator is moved generally to reposition the remote center 324. The linkages 318 of the manipulator 316 can be driven by a series of motors 340. These motors move the linkages 318 actively in response to commands from a processor of the control system. Motors 340 can also be employed to manipulate the surgical tool. Alternative joint configurations and device arrangements are also contemplated. Examples of other joint and device arrangements are disclosed, for example, in U.S. Patent No. 5,878,193, entitled "AUTOMATED ENDOSCOPE SYSTEM FOR OPTIMAL POSITIONING", the entire disclosure of which is incorporated herein by reference. Additionally, although data communication between robotic components and a processor of a robotic surgical system has been preliminarily described herein in connection with communication between a surgical tool and a master controller 301, it should be understood that similar communication can occur between the circuitry of a manipulator, a device joint, an endoscope, or other image capture device, etc., and a processor of a robotic surgical system for component compatibility verification, component type identification, component calibration (such as offset, etc.) communication, component and robotic surgical system connection verification, etc. According to at least one aspect, the various surgical instruments disclosed herein can be used in conjunction with other robotically controlled or automated surgical systems and are not necessarily limited to use with Figures 10 to 12 the specific robotic system components shown and described in the above references.

[0075] Figure 13 A block diagram of a surgical system 1930 for use with one or more surgical instruments, tools, and / or robotic systems in accordance with one or more aspects of the present disclosure is shown. The system 1930 includes control circuitry 1932. The control circuitry 1932 includes a microcontroller 1933, which includes a processor 1934 and a storage medium (such as, for example, a memory 1935).

[0076] The motor assembly 1939 includes one or more motors driven by a motor driver. The motor assembly 1939 is operatively coupled to a drive assembly 1941 to drive or effect one or more motions at the end effector 1940. The drive assembly 1941 can include any number of components suitable for transferring motion to the end effector 1940, such as for example one or more linkages, rods, tubes, and / or cables.

[0077] For example, one or more sensors 1938 provide real-time feedback to the processor 1934 regarding one or more operating parameters monitored during a surgical procedure performed by the surgical system 1930. For example, the operating parameters can be associated with the user performing the surgical procedure, the tissue being treated, and / or one or more components of the surgical system 1930. The sensors 1938 can include any suitable sensors, such as for example magnetic sensors (such as Hall effect sensors), strain gauges, pressure sensors, inductive sensors (such as eddy current sensors), resistive sensors, capacitive sensors, optical sensors, and / or any other suitable sensors.

[0078] In addition to the above, in various arrangements, the sensors 1938 can include any suitable sensors for detecting one or more conditions at the end effector 1940, including but not limited to tissue thickness sensors (such as Hall effect sensors or reed switch sensors), optical sensors, magnetic sensors, force sensors, pressure sensors, piezoresistive membrane sensors, ultrasonic sensors, eddy current sensors, accelerometers, pulse oximeters, temperature sensors, sensors configured to detect electrical properties of a tissue passageway (such as capacitance or resistance), or any combination thereof. As another example, but not limited to this, the sensors 1938 can include one or more sensors located at or around a joint movement joint extending proximally from the end effector 1940. Such sensors can include, for example, potentiometers, capacitive sensors (slide potentiometers), piezoresistive membrane sensors, pressure sensors, or any other suitable sensor type. In some arrangements, the sensors 1938 can include multiple sensors located at multiple positions within the end effector 1940.

[0079] In certain aspects, the system 1930 can include a feedback system 1952 that includes one or more devices for providing sensory feedback to the user. Such devices can include, for example, visual feedback devices (such as LCD displays, touchscreens, LED indicators), audio feedback devices (such as speakers, buzzers), or tactile feedback devices (such as tactile actuators).

[0080] The microcontroller 1933 can be programmed to perform various functions, such as precise control of the speed and position of the drive component 1941. In one aspect, the microcontroller 1933 can be any single-core or multi-core processor, such as those known commercially as ARM Cortex produced by Texas Instruments. In one aspect, the main microcontroller 1933 can be an LM4F230H5QR ARM Cortex-M4F processor core purchased from, for example, Texas Instruments, which includes on-chip memory of 256KB single-cycle flash memory or other non-volatile memory (up to 40MHz), a prefetch buffer for improving performance above 40MHz, 32KB single-cycle SRAM, an internal ROM loaded with software, 2KB EEPROM, one or more PWM modules, one or more QEI analogs and / or one or more 12-bit ADCs with 12 analog input channels, the details of which can be found in the product data sheet.

[0081] The microcontroller 1933 can be configured to calculate a response in the software of the microcontroller 1933. The calculated response is compared with the measured response of the actual system to obtain an "observed" response, which is used for actual feedback decisions. The observed response is a favorable tuning value that equalizes the smooth continuous nature of the simulated response with the measured response, which can detect external influences on the system.

[0082] The motor assembly 1939 includes one or more electric motors and one or more motor drivers. The electric motor can be in the form of a brushed direct current (DC) motor, which has a gearbox and a mechanical connection to the drive component 1941. In one aspect, the motor driver can be an A3941 purchased from Allegro Microsystems, Inc.

[0083] In various forms, the motor assembly 1939 includes a brushed DC drive motor with a maximum rotational speed of approximately 25,000 RPM. In other arrangements, the motor assembly 1939 can include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The motor driver can include, for example, an H-bridge driver including field effect transistors (FETs).

[0084] The motor assembly 1939 can be powered by a power source 1942. The power source 1942 can include one or more batteries, which can include a plurality of battery cells connected in series that can be used as a power source to power the motor assembly 1939. In some cases, the battery cells of the power assembly can be replaceable and / or rechargeable. In at least one example, the battery cell can be a lithium-ion battery, which can be capable of being connected to and separated from the power assembly.

[0085] In addition to the above, the end effector 1940 includes a first jaw 1921 and a second jaw 1931. During a closing movement that transitions the end effector 1940 from an open configuration toward a closed configuration, at least one of the first jaw 1921 and the second jaw 1931 is capable of rotating relative to the other. The closing movement can cause the jaws 1921, 1931 to grasp tissue therebetween. In some arrangements, sensors (such as, for example, strain gauges or microstrain gauges) can be configured to measure one or more parameters of the end effector 1940, such as, for example, the magnitude of the strain applied to one or both of the jaws 1921, 1931 during the closing movement, which magnitude can indicate the closing force applied to the jaws 1921, 1931. The measured strain is converted into a digital signal and provided to, for example, the processor 1934. Additionally or alternatively, sensors (such as, for example, load sensors) can measure the closing force and / or the firing force applied to the jaws 1921, 1931.

[0086] In various arrangements, a current sensor can be employed to measure the current drawn by the motor of the motor assembly 1939. The force required to drive the drive assembly 1941 can correspond to, for example, the current drawn by the motor. The measured force is converted into a digital signal and provided to the processor 1934.

[0087] In one form, a strain gauge sensor can be used to measure, for example, the force applied to tissue by the end effector 1940. The strain gauge can be coupled to the end effector 1940 to measure the force on the tissue being treated by the end effector 1940. In one aspect, the strain gauge sensor can measure the magnitude or amount of strain applied to the jaws of the end effector 1940 during the closing movement, which can indicate tissue compression. The measured strain is converted into a digital signal and provided to the processor 1934.

[0088] Measurements of tissue compression, tissue thickness, and / or the force required to close the end effector on tissue, respectively measured by the sensor 1938, can be used by the microcontroller 1933 to characterize corresponding values of the selected position and / or the speed of one or more components of the drive assembly 1941. In one case, a memory (such as, for example, the memory 1935) can store techniques, formulas, and / or look-up tables that can be employed by the microcontroller 1933 in the evaluation.

[0089] System 1930 may include wired or wireless communication circuitry to communicate with, for example, a surgical hub (e.g., surgical hub 1953), a communication hub, and / or a robotic surgical hub. Additional details regarding the appropriate interaction between system 1930 and surgical hub 1953 are disclosed in U.S. Patent Application Serial No. 16 / 209,423, now U.S. Patent Application Publication No. 2019 / 0200981, entitled "METHOD OF COMPRESSING TISSUE WITHIN A STAPLING DEVICE AND SIMULTANEOUSLY DISPLAYING THE LOCATION OF THE TISSUE WITHIN THE JAWS", the entire disclosure of which is incorporated herein by reference in its entirety.

[0090] In various aspects, control circuit 1932 may be configured to implement the various processes described herein. In certain aspects, control circuit 1932 may include a microcontroller that includes one or more processors (e.g., a microprocessor, a microcontroller) coupled to at least one memory circuit. The memory circuit stores machine-executable instructions that, when executed by the processor, cause the processor to execute machine instructions to implement the various processes described herein. The processor may be any of a variety of single-core or multi-core processors known in the art. The memory circuit may include volatile storage media and non-volatile storage media. The processor may include an instruction processing unit and an arithmetic unit. The instruction processing unit may be configured to receive instructions from the memory circuit of the present disclosure.

[0091] Alternatively, in certain cases, control circuit 1932 may be in the form of a combinational logic circuit configured to implement the various processes described herein. The combinational logic circuit may include a finite state machine that includes combinational logic configured to receive data, process the data by the combinational logic, and provide an output.

[0092] Alternatively, in certain cases, control circuit 1932 may be in the form of a sequential logic circuit. The sequential logic circuit may be configured to implement the various processes described herein. The sequential logic circuit may include a finite state machine. The sequential logic circuit may include, for example, combinational logic components, at least one memory circuit, and a clock. The at least one memory circuit may store the current state of the finite state machine. In certain cases, the sequential logic circuit may be synchronous or asynchronous. In other cases, control circuit 1932 may include a combination of a processor (e.g., processor 1934) and a finite state machine to implement the various processes herein. In other aspects, the finite state machine may include, for example, a combination of a combinational logic circuit and a sequential logic circuit.

[0093] Figure 14 FIG. 600 is a block diagram of a surgical system for use with one or more surgical instruments, tools, and / or robotic systems in accordance with one or more aspects of the present disclosure. Surgical system 600 is similar in many respects to surgical system 1930 and will not be repeated herein in the same detail for the sake of brevity. For example, similar to surgical system 1930, surgical system 600 includes control circuitry that includes a microcontroller 620 having a processor 622 and a memory 624, sensors 630, and a power source 628, which are respectively similar to microcontroller 1933, processor 1934, memory 1935, and power source 1942. Additionally, surgical system 600 includes a plurality of motors and corresponding drive assemblies that can be activated to perform various functions.

[0094] In some cases, a first motor can be activated to perform a first function, a second motor can be activated to perform a second function, a third motor can be activated to perform a third function, and a fourth motor can be activated to perform a fourth function, and so on. In some cases, a plurality of motors can be individually activated to cause, for example, a firing motion, a closing motion, and / or a joint motion in an end effector 1940. The firing motion, the closing motion, and / or the joint motion can be transmitted to the end effector 1940, for example, via a shaft assembly.

[0095] In some cases, system 600 can include a firing motor 602. The firing motor 602 can be operably coupled to a firing motor drive assembly 604 that can be configured to transmit a firing motion generated by the motor 602 to the end effector, specifically for displacing an I-beam element. In some cases, the firing motion generated by the motor 602 can cause, for example, a staple to be deployed from a staple cartridge into tissue captured by the end effector 1940 and / or cause a cutting edge of the I-beam element to be advanced to cut the captured tissue. The I-beam element can be retracted by reversing the direction of the motor 602.

[0096] In some cases, system 600 can include a closing motor 603. The closing motor 603 can be operably coupled to a closing motor drive assembly 605 that is configured to transmit a closing motion generated by the motor 603 to the end effector 1940, specifically for displacing a closing tube to close an anvil and compress tissue between the anvil and the staple cartridge. The closing motion can cause, for example, the end effector 1940 to transition from an open configuration to a closed configuration to grasp tissue. The end effector 1940 can be transitioned to an open position by reversing the direction of the motor 603.

[0097] In some cases, system 600 may include, for example, one or more articulation motors 606a, 606b. Motors 606a, 606b may be operably coupled to respective articulation motor drive assemblies 608a, 608b, which may be configured to transmit the articulation motion generated by motors 606a, 606b to the end effector. In some cases, the articulation motion may, for example, articulate the end effector relative to the shaft.

[0098] As described above, system 600 may include multiple motors, which may be configured to perform various independent functions. In some cases, multiple motors of a surgical instrument or tool may be individually or independently activated to perform one or more functions while other motors remain inactive. For example, articulation motors 606a, 606b may be activated to articulate the end effector while firing motor 602 remains inactive. Alternatively, firing motor 602 may be activated to fire multiple staples and / or advance the cutting blade while articulation motors 606 remain inactive. Additionally, closing motor 603 may be activated simultaneously with firing motor 602 to advance the closing tube and I-beam element distally, as described in more detail below.

[0099] In some cases, system 600 may include a common control module 610, which may be used with multiple motors of a surgical instrument or tool. In some cases, common control module 610 may adjust one of the multiple motors at a time. For example, common control module 610 may be individually coupled to and decoupled from multiple motors of a surgical instrument. In some cases, multiple motors of a surgical instrument or tool may share one or more common control modules such as common control module 610. In some cases, multiple motors of a surgical instrument or tool may independently and selectively engage common control module 610. In some cases, common control module 610 may switch from interfacing with one of the multiple motors of a surgical instrument or tool to interfacing with another of the multiple motors of a surgical instrument or tool.

[0100] In at least one example, common control module 610 may selectively switch between operably engaging articulation motors 606a, 606b and operably engaging firing motor 602 or closing motor 603. In at least one example, as Figure 14As shown, switch 614 can move or transition between multiple positions and / or states. For example, in a first position 616, switch 614 can electrically couple the common control module 610 to the firing motor 602; in a second position 617, switch 614 can electrically couple the common control module 610 to the closing motor 603; in a third position 618a, switch 614 can electrically couple the common control module 610 to the first joint movement motor 606a; and in a fourth position 618b, switch 614 can electrically couple the common control module 610 to the second joint movement motor 606b. In some cases, the separate common control module 610 can be electrically coupled to the firing motor 602, the closing motor 603, and the joint movement motors 606a, 606b simultaneously. In some cases, switch 614 can be a mechanical switch, an electromechanical switch, a solid-state switch, or any suitable switching mechanism.

[0101] Each of motors 602, 603, 606a, 606b can include a torque sensor to measure the output torque on the shaft of the motor. Force on the end effector can be sensed in any conventional manner, such as by a force sensor on the outer side of the jaws or by a torque sensor of the motor used to actuate the jaws.

[0102] In various cases, as Figure 14 shown, the common control module 610 can include a motor driver 626, which can include one or more H-bridge FETs. The motor driver 626 can modulate the power transmitted from the power source 628 to the motors coupled to the common control module 610 based on inputs received from, for example, a microcontroller 620 (“controller”). In some cases, when a motor is coupled to the common control module 610, the microcontroller 620 can be used, for example, to determine the current consumed by the motor, as described above.

[0103] In various cases, the processor 622 can control the motor driver 626 to control the position, rotational direction, and / or speed of the motors coupled to the common controller 610. In some cases, the processor 622 can signal the motor driver 626 to stop and / or deactivate the motors coupled to the common controller 610.

[0104] In some cases, the memory 624 can include program instructions for controlling each of the motors of the surgical instrument 600 that can be coupled to the common controller 610. For example, the memory 624 can include program instructions for controlling the firing motor 602, the closing motor 603, and the joint movement motors 606a, 606b. Such program instructions can cause the processor 622 to control the firing function, the closing function, and the joint movement function based on inputs from an algorithm or control program of the surgical instrument or tool.

[0105] In some cases, one or more mechanisms and / or sensors such as sensor 630 can be used to alert the processor 622 of the program instructions that should be used in a particular setting. For example, sensor 630 can alert processor 622 to use program instructions associated with firing, closing, and articulating the end effector. In some cases, sensor 630 can include, for example, a position sensor that can be used to sense the position of switch 614. Thus, processor 622 can use program instructions associated with the I-beam of the firing end effector when, for example, sensor 630 detects that switch 614 is in the first position 616; processor 622 can use program instructions associated with closing the anvil when, for example, sensor 630 detects that switch 614 is in the second position 617; processor 622 can use program instructions associated with articulating the end effector when, for example, sensor 630 detects that switch 614 is in the third position 618a or the fourth position 618b.

[0106] As disclosed above, the electrosurgical suturing system consists of multiple mechanical and electrical subsystems. These components can include, but are not limited to, an end effector composed of a first jaw and a second jaw, where the first jaw is configured to include a staple cartridge and the second jaw includes an anvil configured to be able to hold one or more staples onto the tissue grasped by the jaws when the jaws are closed. The end effector can also include a blade or a tissue cutting edge that can reciprocate to cut the tissue once one or more staples are attached to the tissue. The end effector can be mounted on a shaft assembly, which can also include an articulation joint. The articulation joint can be configured to be able to rotate about an articulation axis, thereby enabling the end effector to rotate about the articulation axis relative to the longitudinal axis of the shaft assembly.

[0107] In some aspects, the user can use a manual trigger mechanism to close the anvil onto the tissue supported by the first jaw. In an alternative aspect, when the trigger mechanism is depressed, the anvil can be closed onto the first jaw by a motor-actuated drivetrain powered by a motor power source. In some aspects, the reciprocating movement of the blade or the tissue cutting edge can be driven by an electrically activated motor. In some other aspects, the articulation joint can be rotated by the same electrically activated motor that drives the blade or a separate motor. The motor can be controlled by a combination of an activation switch and one or more motor controllers through a series of motor control signals.

[0108] Thus, as disclosed above, an electrosurgical suturing device consists of multiple high-precision mechanical components that work together to achieve tissue suturing and cutting. In some subsystems, the mechanical components can work together to cause the blade to slide in the distal direction to cut tissue and then slide back to the starting position once the cutting operation is complete. In another subsystem, the mechanical components can work together to cause the articulation joint to rotate in a first direction and then return to a second position. In yet another subsystem, the mechanical components can work together to cause the anvil to close on the first jaw, thereby compressing and suturing the tissue, and then cause the anvil to move away from the first jaw after the tissue has been compressed and sutured. These subsystems may require multiple mechanical linkages (drivelines) to interact with a motor with or without a gear reducer assembly. One or more sensors can be used to detect the type and speed of movement of the components of the driveline, thereby serving as feedback to the motor controller.

[0109] The motor controller can include one or more algorithms implemented in hardware, software, or firmware that are designed to actuate the driveline in response to the surgical environment. In one aspect, the surgical environment can reflect the type or thickness of the tissue being grasped, sutured, and cut in the jaws. In another aspect, the surgical environment can reflect obstacles around the articulation joint. In yet another aspect, the surgical environment can reflect the thickness of the tissue being compressed and sutured by the anvil and the first jaw. The motor controller should be configured to adjust the motor control signal such that the activation of one or more motors can be optimized for the task at hand.

[0110] Additionally, the electrosurgical suturing system can be designed to actively make small performance corrections to eliminate any performance deficiencies in subsystems such as the tissue cutting subsystem, the jaw clamping subsystem, or the articulation subsystem. These adjustments can be measured against past historical data from previous cycles or predicted for subsequent cycles based on trend performance. These types of enhancements can standardize the performance of the device during repeated use or standardize manufacturing variations in performance between devices.

[0111] In the operation of various DC motors, the motor operation can be controlled by a pulse width modulation (PWM) system. The PWM system generates a signal based on a base frequency defined by the period during which current pulses are supplied to the motor. Each current pulse occurs during some portion of the period of the base frequency and can represent any percentage of the period from 0% (no current supplied during the period) to 100% (current supplied throughout the period). The motor speed can depend on the portion of the period during which current is supplied. Thus, the motor speed can be modulated by the pulse width of the current during the period.

[0112] Typically, the PWM pulse train consists of square wave signals, where the current pulses are switched on or off at a fixed current during the pulse duration. The motor can be actuated during the current-on phase and can be non-actuated when the current is switched off. This rotational movement can be transmitted to a gear reducer assembly mechanically coupled to the motor. The gear reducer assembly is then mechanically coupled to one or more components of the drive train, for example, associated with the rotational movement of an anvil, the lateral movement of a tissue cutting blade, or the rotational movement of a joint movement joint. Under ideal conditions, the movement associated with the gear reducer assembly and the associated components of the drive train will move synchronously with the movement of the motor and with the square pulse train of the PWM motor control signal. Thus, all drive train components can move during the current-on phase and can be non-actuated when the current is switched off.

[0113] However, there may be non-idealities in the movement of the gear reducer assembly and the drive train components. Such non-idealities can include, but are not limited to, gear backlash, viscosity at gear joints, friction at smooth component joints, and bending of elongated components such as firing members, joint movement systems, or firing shaft portions. It can be further recognized that such mechanical non-idealities can change over time to reflect wear and use of mechanical components. Thus, the movement of the gear reducer assembly and the drive train components may not follow the sharp rise and fall of the current pulse train. Therefore, it would be useful to modify the shape of the PWM current pulse such that the mechanical components will be more consistent with the PWM current output. In this way, the mechanical coupling of the motor to the overall system response can be achieved by adapting the motor control signal to the system configuration or physical characteristics of the components of the drive train. Such control system adaptation can compensate for the differences between the previously determined surgical stapling system and a nominal, ideal, or average system.

[0114] The motor control algorithm can be adjusted based on the detection of the characteristics of the individual device drive train. The electrosurgical stapler system can monitor the response of the system drive train relative to the input motor control signal and adjust the input control signal based on the individual system response relative to a pre-established baseline performance. In some non-limiting aspects, the monitored response may be frictional losses, acceleration or deceleration response to a step input signal, PID control variations, harmonics of the system, noise, or force / velocity of the motor. In some aspects, the adaptation of the motor control algorithm can include modifications to the PID control parameters, trigger delay for dynamic braking, level or functional window around the trigger threshold, power, current, voltage, or PWM signal.

[0115] In some aspects, the variation of the waveform of the PWM signal (as current or voltage to the motor) can include driving the motor using a bit stream controller based on delta-sigma modulation (DSM). The DSM can be substantially configured to generate a quasi-PWM signal in hardware by simulating the output. Figure 15A block diagram showing an example of a DSM controller 8000 is presented. In the example of the DSM controller 8000, a signal input 8002 enters the positive branch of a first adder 8004. The output of the first adder 8004 is provided to a first signal integrator 8006. The output of the first signal integrator 8006 is used in the positive branch of a second adder 8008. The output of the second adder 8008 is integrated by a second signal integrator 8010. The output of the second signal integrator 8010 becomes the input to a comparator 8012. It can be understood that the signal input 8002 and the outputs of the first adder 8004, the first signal integrator 8006, the second adder 8008, and the second signal integrator 8010 are all analog signals. The output of the comparator 8012 is a digitized signal ranging from a first (low) voltage to a second (high) voltage. The output of the comparator 8012 becomes the input to both a digital filter 8016 and a 1-bit digital-to-analog converter (DAC) 8018. The DAC output 8020 is used in a negative feedback manner in the negative branches of both the first adder 8004 and the second adder 8008. The output 8022 of the digital filter 8016 can be used as a motor control signal.

[0116] The DSM signal can be used to control the waveform shape of the motor control signal to compensate for changes in the performance of the motor, gears, or driveline due to friction, component tolerance variations, component mating, or wear. The adjusted motor control signal can be characterized as an irregular PWM that can be used to simulate a ramp response (instead of a traditional sine curve) to drive the motor. Figure 16 A graph 8100 showing the ratio of some irregular PWM motor control signals to the desired driveline component response is presented. The y-axis of the graph 8100 represents any control metric, such as component speed, motor signal amplitude, or current, etc. The x-axis of the graph 8100 represents the movement of the driveline component from its minimum position (Min) to its maximum position (Max). The ideal waveform 8102 is a square wave corresponding to the movement of the driveline component for a square wave current input to the motor. The irregular PWM wave signals 8104a, 8104b, and 8104c can overcome the non-ideality of the driveline component movement (due to friction, viscosity, and other effects disclosed above). Therefore, the irregular PWM wave signals 8104a, 8104b, and 8104c can result in better control of the driveline component movement.

[0117] In some aspects, in addition to the regular PWM wave signal, an irregular PWM wave signal may be used intermittently. For example, the irregular PWM wave signal may be used only when the powertrain components are moving within a portion of their full range of motion. Thus, the irregular PWM wave signal may be used when the powertrain components correspond to a subsystem operating within a locked zone and not used when the subsystem is operating within the remainder of the range of motion. In one non-limiting example, during the last 0.02" of the closing tube stroke of the tissue cutting blade relative to the first 0.23".

[0118] Alternatively, the irregular PWM wave signal may be used throughout the full range of motion of the powertrain components. Additionally, the pulse shape of the irregular PWM wave signal may be adjusted over time. Non-limiting examples of pulse shape changes may include adjusting the leading edge of the signal in a different manner than the trailing edge of the irregular PWM wave signal (e.g., triangular rise edge versus square trailing edge). Such different edge shapes may be used to compensate for frictional losses at the start of motion rather than at the end of motion. Thus, the leading edge of the signal describes the rising profile of the "on" time of the motor, while the trailing edge of the signal describes the falling profile starting from the "on" time of the motor. These asymmetric adjustments to the motor signal profile may be used for tissue that may respond to different types of leading and trailing edge motion of the tissue cutting blade. The electrosurgical suturing system may detect the slope of a leading or trailing signal indicative of system response based on the set profile. The electrosurgical suturing system may then adjust the next profile to react to the system and provide enhanced control performance for the benefit of patient outcomes.

[0119] Figure 17 A flowchart 8200 showing a method of controlling a motor in an electrosurgical suturing system based on changing the shape of a motor control signal is shown. The motor controller may apply 8202 a first motor control signal, such as a square wave PWM control signal. The motor controller may then receive 8204 data associated with the operation of one or more components of the drive train. Such data may include, but is not limited to, the position, velocity, acceleration, or deceleration of one or more components of the drive train during their respective motion. Such data may be obtained from sensors configured to detect such data, such as position sensors. The motor controller may compare 8206 the data associated with the operation of the drive train with baseline data associated with the operation of the drive train. Such baseline data may be obtained from manufacturer testing or acceptance trials, or may be obtained from the electrosurgical suturing system during its initial use. The motor controller may apply 8208 a second motor control signal based on the comparison. The second motor control signal may differ from the first motor control signal in terms of the pulse train shape of the first motor control signal. Changes in the pulse train shape may reflect changes in pulse amplitude, changes in the leading edge, changes in the trailing edge, or other changes in the pulse train shape. As described above, in some aspects, such changes may result in an irregular PWM control signal.

[0120] In some aspects, data associated with the operation of the drivetrain may include data associated with frictional losses of the drivetrain, acceleration response of the drivetrain, deceleration response of the drivetrain, or mechanical harmonics of the drivetrain.

[0121] In some additional aspects, applying the first motor control signal may include using a bitstream controller based on delta-sigma modulation to generate the motor control signal. In an alternative aspect, applying the second motor control signal may include using a bitstream controller based on delta-sigma modulation to generate the motor control signal.

[0122] In yet another aspect, applying the second motor control signal may include adjusting PID control parameters, a delay for triggering a dynamic braking function, changing a level or function window near a trigger threshold, adjusting the power applied from a motor power source to the motor, or adjusting a pulse-width modulation signal applied to the motor. In a non-limiting example, adjusting the pulse-width modulation signal applied to the motor may include adjusting the shape of the rising portion, maximum amplitude portion, or falling portion of the pulse-width modulation signal.

[0123] In some other aspects, it may be useful to characterize one or more functions of a subsystem of the electrosurgical suturing system during operation. Such characterization may be useful if a fault condition or abnormal behavior is detected during surgery. Examples of fault conditions may include, but are not limited to, stall conditions in the operation of, for example, a tissue cutting blade or in the rotational movement around a joint movement joint. The motor control signal may be reduced under load, and when the motor is in a stall or full-torque condition, a perturbation signal of a known frequency may be applied to the motor in order to extract drivetrain load information. The perturbation signal may be introduced into the regular motor control signal during the operation of the drivetrain in order to interrogate combined subsystem component losses.

[0124] One type of perturbation signal can be characterized as the "load jitter" signal of the system. The "jitter" signal can be a signal that causes a subsystem component to operate alternately in the forward and reverse directions at a frequency higher than the standard operating frequency. The motor controller can use this signal to derive the load information of the system based on motor operation. "Load jitter" or load fluctuations can be used to determine the amount of current used by the motor and thus characterize the load on the drivetrain. Such motor load fluctuations can be used to additionally interrogate the combined drivetrain component losses while the drivetrain is in motion (e.g., how quickly the entire drivetrain slows down when the motor load decreases by a predetermined amount). Additionally, the inertial aspects of the drivetrain can be determined. Examples of inertial aspects can include how quickly the system re-accelerates from an initial slower speed to a preset higher speed given a known motor signal input power. When the drivetrain is driven to a portion of the stroke where the system cannot move, a jitter signal can be applied. Exemplary conditions that result in a stall condition can include driving a tissue cutting blade into a locking tab or into a fully retracted proximal position. Similarly, the inertia of the tissue cutting blade subsystem drivetrain can be characterized in a portion of the tissue cutting blade subsystem drivetrain motion that has no additional losses, such as at the first 0.150" traveled by the drivetrain before engaging the anvil cam while the tissue cutting blade remains in the anvil pit. Analysis of the response to the jitter signal under such conditions can help characterize the motor stall condition and can be used to update the motor and / or drive operation calibration.

[0125] As disclosed above, a perturbation signal can be applied to a typical motor control signal in order to characterize the operation of one or more subsystems of an electrosurgical suturing system. The "jitter" signal has been disclosed above. Another type of signal can be a "chirp" signal. A chirp signal can be considered a short-duration electrical signal where the signal frequency increases and / or decreases over time. A chirp signal can be used to characterize the system response over a frequency range that includes the chirp. Like the jitter signal, the chirp signal can be superimposed on the motor control signal during motor operation. Alternatively, the term chirp and frequency sweep signal can be used interchangeably. The frequency changes caused by the chirp signal can be coupled with the PWM motor control signal generated by the motor controller in order to interrogate the differences in motor output at different speed and torque performance levels. The response of the motor can allow for the diagnosis of system stability and the mechanical elements of the drive system within a certain frequency range. The spectral analysis of motor responses such as speed, acceleration, deceleration, or torque can be monitored to determine, for example, inertia, damping, losses, recoil, and tolerance slopes, where the threshold of the returned signal is used to determine if any adjustment to the motor control signal is needed. In some aspects, the jitter signal can be considered a type of chirp signal.

[0126] In another aspect, the response of the motor or drive train of an electrosurgical suturing system can be determined by applying a step function signal to the motor. The step function signal can be used to characterize the motor response delay to improve the estimation of future input speed targets. The motor response to the step function and the response of any components of the drive train that are mechanically coupled to the motor can be measured. In one non-limiting example, the change in the speed of the motor or drive train component can be measured over a period of time after the step function signal is applied. Figure 18 Graph 8300 shows the response of motor speed 8304 over time to the application of step function signal 8302. In another example, the measurement results of the time delay of the step function signal in response to the motor and / or drive train components can also be analyzed. The time delay of the motor's response to the applied step function signal can characterize the electrodynamics of the motor, such as the resistance and / or inductance of the motor windings. The motor winding inductance can slow down the overall response of the system. Additionally, the motor mechanical dynamics, such as rotor inertia and / or friction, can be evaluated. The analysis of the motor's response to the step function signal can also indicate that the motor shaft is not perfectly straight, which may result in additional friction on the system. The non-linearity of the motor shaft can also affect the inertia of the system.

[0127] In some aspects, the motor used in an electrosurgical suturing system can include a DC brushed motor. The brushes are used to transfer energy from the motor control signal to the entire motor commutator. The commutator can be a rotary electrical switch that periodically reverses the direction of the current between the rotor and the external circuit. The brushes can be pressed against the commutator, thus making sliding contact with successive segments of the commutator as the commutator rotates. The windings (coils) on the armature are connected to the segments of the commutator. Changes in the brush pressure can cause changes in the system friction. Additionally, changes in the shape of the motor brushes can alter the amount of current supplied to the commutator. Further, changes in the brush shape can increase the friction between the brushes and the commutator, thus affecting the motor performance. In one aspect, the contact between the brushes and the commutator can be intermittent ("brush chatter"). As a result of brush chatter, the brushes may partially or completely fail to make electrical contact with the commutator. Consequently, the current flowing to the commutator can be reduced, modulated, or even interrupted. This results in an inconsistent motor torque generation ability.

[0128] Figure 19 and Figure 20A DC brushed motor including its brush and commutator is shown. The DC brushed motor 8400a includes an unworn brush 8402a in contact with the commutator 8404a. The DC brushed motor 8400b includes a worn brush 8402b in contact with the commutator 8404b. It can be observed that the unworn brush 8402a is flat and forms a single electrical and mechanical contact point with the commutator 8404a. The single contact point is the only contact point that allows current to flow through each successive segment as the commutator 8404a rotates. The worn brush 8402b is rounded and can make multiple electrical and mechanical contacts with multiple segments of the commutator 8404b as it rotates. It can be recognized that multiple contacts may cause the worn brush to be in electrical contact with multiple successive segments of the commutator 8404b simultaneously. This may affect the smoothness of the rotor rotation.

[0129] In one aspect, an electrosurgical suturing system may include a motor gear reducer assembly in mechanical communication with a motor shaft. Before being assembled into the surgical suturing system, the motor gear reducer assembly and its associated motor may be tested using, for example, a step function input, and characteristics associated with the motor having the motor gear reducer assembly operation may be collected. Data for such an initial motor having the motor gear reducer assembly may include output speed, no-load running current, and many other electrical parameters of the motor. Mechanical aspects, such as gear recoil and friction that varies during operation, may also be collected. Once assembled into the device, the motor having the motor gear reducer assembly may be integrated into a larger mechanical system. By applying power to the motor having the motor gear reducer assembly and rerunning the same characterization tests in the forward and reverse directions, information about the system including the motor may be characterized. A comparison of the data for the initial motor having the motor gear reducer assembly with the data obtained from the motor having the motor gear reducer assembly in the complete electrosurgical suturing system after use may clarify the friction requirements of the entire system. In some aspects, the characterized friction response of the motor having the motor gear reducer assembly may be different between the forward and reverse directions. It should be understood that due to the interaction of the tissue cutting blade and the tissue, the cutting blade moving in the forward direction may encounter additional friction. However, when the tissue cutting blade operates in the reverse direction away from the tissue, it is expected that the blade movement friction should decrease because no tissue acts on the tissue cutting blade. The initial forward and reverse friction responses of the tissue cutting blade in the unused device may be used to set a threshold for the operation of the tissue cutting blade. In this way, the user of the electrosurgical suturing system may receive a warning about the additional friction generated due to tissue being cut rather than the inherent friction in the tissue cutting blade subsystem.

[0130] Generally speaking, it can be understood that the initial operations of the various subsystems of an electrosurgical suturing system can be used to collect initial data regarding the motor, the motor gear reducer assembly, and the drivetrain components. The motor can be coupled to each individual subsystem, such as the articulation subsystem and the tissue blade subsystem, to characterize the motor and / or the motor gear reducer assembly. When the motor is coupled to the subsystem, the motor can be operated at various speeds and directions to characterize its operation. Parameters that can be characterized for the motor and / or the motor gear reducer assembly can include, but are not limited to, recoil and the delay from receiving a motor control signal to operating a mechanical component. By characterizing these timings, the motor controller algorithm can be adjusted to minimize these delays.

[0131] Figure 21 A flowchart 8500 illustrating a method of characterizing a motor in an electrosurgical suturing system is shown. The motor controller can transmit 8502 a perturbation signal to the motor. In one example, the perturbation signal can include a step signal. In another example, the perturbation signal can be transmitted to the motor along with an operating motor control signal. In some examples, the perturbation signal transmitted along with the operating motor control signal can include a chirp signal or a jitter signal. The motor controller can receive 8504 one or more motor function parameters. Non-limiting examples of motor function parameters can include a motor delay parameter, a motor frequency-dependent torque parameter, or a motor current draw parameter. The motor controller can determine 8506 one or more electrosurgical stapler system characteristics based on the one or more motor function parameters. Non-limiting examples of electrosurgical stapler system characteristics can include system friction, system inertia, system recoil, or system delay. The motor controller can then adjust 8508 one or more functions of the motor controller. Examples of motor controller functions that can be adjusted in response to the system characteristics can include, but are not limited to, the motor drive pulse width modulation phase, the motor drive frequency, or the motor drive current.

[0132] In some aspects, one or more motors of an electrosurgical suturing system may include a stepper motor. A stepper motor is a digitally controlled brushless DC motor that divides a complete rotation of a rotor into a number of equal steps. A stepper motor includes a plurality of electromagnets arranged around a central rotor. When each electromagnet is energized, the rotor rotates a fixed amount. When the electromagnets are energized sequentially, for example, by a series of pulse trains, the rotor rotates in synchronism with the energized electromagnets. A stepper motor may be characterized according to several different torque values. In one aspect, the pull-in torque may represent the amount of torque by which the motor can move a load without acceleration. Generally speaking, the pull-in torque-speed curve shows the speeds at which the motor can start, stop, and reverse without losing synchronism with the input pulses. The pull-out torque may relate to the amount of torque that the motor can dynamically generate at various speeds. Generally speaking, this torque may be represented in a conventional torque-speed curve. If the motor exceeds this torque, it loses synchronism with the input pulses and stalls. The holding torque may represent the amount of external torque that must be applied to the motor shaft when the motor is at full rated current and stationary (zero speed). This condition may be met when only a single electromagnet is energized and the motor is not moving. This is a static torque and is generally not depicted on the torque-speed curve. The holding torque is typically about 20% higher than the low-speed torque of the dynamic torque-speed curve. Finally, the detent torque represents the amount of torque required to move the motor rotor when the motor is not energized. This condition is met when no current is flowing through the windings and the motor is stationary.

[0133] Figure 22 FIG. 8600 is a diagram showing various speed and torque curves of a stepper motor that can be used in an electrosurgical suturing system. Curves 8602a and 8602b depict the maximum speed and torque curves of the stepper motor under various conditions. As described above, curves 8602a and 8602b may represent the pull-out torque of the stepper motor. The initial maximum speed and torque curve 8602a shows the maximum speed that the motor can achieve under various load conditions. Under the no-load condition 8604a, the motor can reach its maximum speed. As the load increases and the motor is required to generate more torque, the maximum speed may decrease until the motor reaches the stall torque 8606a. The stall torque 8606a occurs when the motor cannot move due to the load. The initial speed and torque curve 8602 can be obtained from a motor operating alone. For example, the initial speed and torque curve 8602 can be a speed and torque curve provided by the motor manufacturer. The parameters or data related to the initial speed and torque curve 8602 can be obtained from the manufacturer and stored in the memory unit of the motor controller. Alternatively, the parameters or data related to the initial speed and torque curve 8602 can be obtained by independent measurements made on a separate motor or in conjunction with a motor gear reduction assembly. The data can be stored directly in the memory unit of the motor controller, or it can be read from an external memory device (such as a chip or a thumb drive), or it can be downloaded from a server of a remote communication system.

[0134] Once the motor is installed in the electrosurgical suturing system, the motor is required to move the various components of the drive train. Due to the various friction characteristics of the components of the drive train, the speed-torque curve 8602b of the entire mechanical subsystem may shift downward (arrow A) to a lower value. Additionally, as the electrosurgical suturing system is used, additional friction and wear may occur in the drive train components, further reducing the speed-torque curve 8602b. It will be appreciated that the motor and / or the motor gear reducer assembly may suffer wear, including, as a non-limiting example, loss of concentricity of the motor shaft, rotor, or gear reducer assembly. All of these effects may further reduce the speed-torque curve 8602b. The reduction of the speed-torque curve 8602b may result in a reduction of both the maximum speed 8604b under no-load conditions and the maximum achievable torque (as measured at the stall torque 8606b).

[0135] Curves 8608a, 8608b represent the minimum speed (or current) versus torque curves. These curves show the minimum speed or current required for the motor to produce a particular amount of torque. Curve 8608a may represent the minimum speed or current required for the motor alone or for the motor in combination with only the motor gear reducer assembly to produce torque. Under no-load conditions 8610a, the motor may require a minimum speed or current to overcome its internal resistance. In some aspects, the no-load minimum speed or current 8610a may represent the speed or current required to overcome the positioning torque. The minimum speed or current capable of producing the maximum torque 8612 may be related to the stall torque.

[0136] Once the motor is installed in the electrosurgical suturing system, the motor is required to move various components of the drive train. Due to the various friction characteristics of the components of the drive train, the minimum speed or current-versus-torque curve 8608b of the entire mechanical subsystem may shift upward (arrow B) to a higher value. Thus, even under no-load condition 8610b, the minimum speed or current required to overcome the resistance of the complete drive train will be greater than the no-load condition 8610a of the minimum speed or current-versus-torque curve 8608a of the motor alone. In addition, as the electrosurgical suturing system is used, additional friction and wear may occur in the drive train components, further increasing the minimum speed or current-versus-torque curve 8608b. It will be appreciated that the motor and / or the motor gear reducer assembly may suffer wear, including, as a non-limiting example, loss of concentricity of the motor shaft, rotor, or gear reducer assembly. All these effects may further increase the minimum speed-versus-torque curve 8608b. The increase in the minimum speed or current-versus-torque curve 8608b may result in an increase in the minimum speed or current under no-load condition 8610b, but the minimum speed or current at maximum torque 8612 may not be affected. However, the minimum current during motor operation may cause the motor coils to heat up. As the coils heat up, their resistance may increase, reducing the amount of current flowing through the motor windings. The reduction in motor current due to the temperature-dependent change in winding resistance may result in a reduction in the minimum speed or current at maximum torque 8612, as shown by arrow C.

[0137] Figure 23 A flowchart 8700 showing a method of controlling a stepper motor in an electrosurgical suturing system is shown. The motor controller may apply 8702 a motor control signal to the stepper motor. The motor controller may receive 8704 data associated with the operation of the stepper motor coupled to the drive train. The motor controller may compare 8706 the data associated with the operation of the stepper motor coupled to the drive train with baseline data associated with the operation of the uncoupled stepper motor. In some non-limiting examples, the baseline data may include one or more of the motor pull-in torque, motor pull-out torque, or motor holding torque of the uncoupled stepper motor. The motor controller may then adjust 8708 the motor control signal based on the comparison. Examples of motor controller signals that may be adjusted in response to the comparison may include, but are not limited to, the motor drive frequency, the motor drive pulse width, or the motor drive current.

[0138] As disclosed above, a motor in an electrosurgical suturing system can be coupled to one or more drivetrain components. In some non-limiting examples, the drivetrain can include a drivetrain for actuating a tissue cutting blade or a drivetrain for actuating an articulating joint. The drivetrain can be composed of multiple components that are mechanically coupled to each other. In some aspects, the motor can directly drive the drivetrain, or the motor can drive the drivetrain through a motor gear reducer assembly. It can be appreciated that each mechanical component of the drivetrain can exhibit its own mechanical operation, which may be subject to friction, viscosity, and recoil related to the shape and connection of the components. While it is useful to know the overall operation of the drivetrain, it may be important to characterize the abnormal operation of each drivetrain component in order to better characterize the entire motor plus drivetrain assembly. Therefore, differentiated measurement and analysis of at least two separate parts of the connected or coupled drivetrain can ensure better mechanical operation (verification of response) or quantify losses / inefficiencies that may differ between the ideal or expected response and the actual response of the system.

[0139] In some aspects, the motor controller algorithm can include detection of the characteristics of individual device drivetrain components. The electrosurgical suturing system can monitor the operation of the subsystem drivetrain components relative to the input motor control signal based on data obtained from sensors that drive the movement of the drivetrain components. The motor controller algorithm can then adjust the motor control signal based on the individual system response relative to a pre-established baseline performance. In some non-limiting aspects, the monitored responses can be friction losses, acceleration or deceleration responses to a step input signal, PID control variations, harmonics of the system, noise, or force and speed. Adjustment of the motor control algorithm can include adjustment of PID control parameters, trigger delay of dynamic braking, level or functional window around the trigger threshold, motor power, motor current, motor voltage, or PWM signal characteristics.

[0140] In some aspects, multiple sensors can be configured to monitor separate components of the same drive system so that the system can detect the slope, recoil, or losses of each component. In one non-limiting example, the rotational data from a rotary encoder coupled to the shaft of the motor can be compared with the rotational data from an encoder coupled to the motor gear reduction assembly. The firing rack can be coupled to the motor gear reduction assembly. The comparison between the data from the motor shaft encoder and the motor gear reduction assembly can be used to determine the recoil, slope, backlash, and other losses of the motor gear reduction assembly. This comparison can result in better compensation by the motor controller, which can then adjust one or more functions of the motor controller, including but not limited to the target motor speed, PID duty cycle of the PWM, voltage limit, or current limit. By adjusting one or more motor controller functions, the motor controller can cause the motor to operate the drivetrain at a desired operating speed, braking, and holding.

[0141] In some aspects, the sensor may be coupled to a drive rod actuated by a motor. An encoder associated with the motor shaft may provide rotational data for the operation of the motor, while a drive rod sensor may sense the linear actuation of the drive rod. Data from the encoder and the drive rod sensor may be used to calculate a mechanical transfer function between the motor rotational speed and the linear movement of the drive rod. The transfer function may help determine the delay in the response of the drive rod to the motor movement. The resulting analysis may provide a measurement of the gear "slope" or recoil and be able to determine the requirements for recoiling in a tensioned gear train. In this way, the motor response delay may be characterized to improve the estimation of future input speed targets by the motor controller algorithm.

[0142] In another aspect, the sensor may be associated with a clamping trigger and an anvil / channel area. The motor controller may determine the movement and timing of the closing trigger. The motor controller may then sense the movement of the anvil. Using this data, the motor controller may determine the time delay between the input of the closing trigger and the movement of the anvil. Such data may be obtained for both the opening and closing functions of the anvil. As disclosed above, a transfer function based on sensor data and motor rotation data may be used to estimate the motor rotational speed in order to reduce the position / speed error of the device.

[0143] Figure 24FIG. 8800 is a flow chart showing a method of controlling a motor in an electrosurgical suturing system based on data received from multiple sensors of the operation of subsystem components. The motor controller may receive 8802 rotational data from a first rotational sensor attached to the motor shaft. The first rotational sensor may be, for example, a rotary encoder position sensor. The motor controller may then receive 8804 gear rotational data from a second rotational sensor attached to the output shaft of the gear reducer assembly. Similarly, in some non-limiting examples, the second rotational sensor may be a rotary encoder position sensor. The motor controller may also receive additional sensor data, such as trigger motion data from a motion sensor mechanically coupled to the anvil clamping trigger or anvil position data from an anvil position sensor. The motor controller may calculate 8806 a mechanical transfer function based at least in part on the rotational data and the gear rotational data. In some alternative aspects, the motor controller may also receive linear motion data from a linear position sensor of the drive rod. The motor controller may then calculate a second mechanical transfer function based at least in part on the rotational data, the gear rotational data, and the linear motion data. The motor controller may also include a motor response delay. The motor controller may determine 8808 the mechanical system non-ideality of the electrosurgical suturing system. The mechanical non-ideality may include, but is not limited to, system component delays, recoil, gear slope, gear backlash, and mechanical losses of the gear reducer assembly. The motor controller may modify 8810 the motor control signal based on the determined mechanical system non-ideality. In some aspects, the motor controller may modify one or more of the motor control signal voltage, the motor control signal current, and the motor control pulse duty cycle. In some additional aspects, the motor controller may receive trigger motion data from a motion sensor mechanically coupled to the anvil clamping trigger and anvil position data from an anvil position sensor. The motor controller may then determine the time delay between the motion of the anvil clamping trigger and the motion of the anvil.

[0144] As disclosed above, the electrosurgical suturing system consists of multiple mechanical and electrical subsystems. These components may include, but are not limited to, an end effector consisting of a first jaw and a second jaw, where the first jaw is configured to include a staple cartridge and the second jaw includes an anvil. When the first jaw and the second jaw are closed, they cooperate to deploy staples into the tissue grasped by the jaws. The end effector may also include a blade or tissue cutting edge that is movable to cut the sutured tissue. The end effector may be mounted on a shaft assembly that may also include an articulation joint. The articulation joint may be configured to be able to rotate about an articulation axis, thereby rotating the end effector about the articulation axis relative to the longitudinal axis of the shaft assembly.

[0145] In some aspects, a user may use a manual trigger mechanism to close the anvil onto tissue supported by the first jaw. In some aspects, the tissue cutting blade may be driven by an electrically activated motor. In some other aspects, the articulation joint may be rotated by the same electrically activated motor that drives the cutting blade or by a separate motor. The motor may be controlled by a combination of an activation switch and one or more motor controllers via a series of motor control signals.

[0146] Thus, as disclosed above, an electrosurgical suturing system consists of multiple high-precision mechanical components that work together to effect the suturing and cutting of tissue. In some subsystems, the mechanical components may work together to cause the cutting blade to slide in a distal direction to cut tissue and then slide back to its starting position once the cutting operation is complete. In some other subsystems, the mechanical components may work together to cause the articulation joint to rotate in a first direction and then return to a second position. These subsystems may require multiple mechanical linkages (drivelines) to interact with a motor with or without a gear reducer assembly. One or more sensors may be used to detect the type and speed of movement of the driveline and thus serve as feedback to the motor controller.

[0147] The motor controller may include one or more algorithms implemented in hardware, software, or firmware that are designed to actuate the driveline in a manner responsive to the surgical environment. In one aspect, the surgical environment may reflect the type or thickness of the tissue being grasped, sutured, and cut in the jaws. In another aspect, the surgical environment may reflect obstacles around the articulation joint. The motor controller should be configured to adjust the motor control signals such that the activation of one or more motors can be optimized for the task at hand.

[0148] Additionally, the electrosurgical suturing system may be designed to actively make small performance corrections to eliminate any performance deficiencies in subsystems such as the tissue cutting subsystem, the jaw clamping subsystem, or the articulation movement subsystem. These adjustments may be measured against past historical data from previous cycles or predicted for subsequent cycles based on trending performance. These types of enhancements may standardize the performance of the device during repeated use or standardize manufacturing variations in performance between devices.

[0149] Time (aging) and use can cause structural changes in the components of the driveline and in one or more motors. Narrow and elongated structures such as drive members, intermediate firing shaft sections, firing members, articulation locking levers, articulation levers, and articulation systems may warp or bend due to continued use. The teeth of the gears in the gear reducer assembly may crack, bend, or wear due to use. In some aspects, the plastic gears that make up the gear reducer assembly may become brittle and crack due to aging. It can be understood that unless the motor controller is able to adapt the motor control signals to mechanical changes in the motor and driveline, the subsystems may become less responsive to the motor control signals.

[0150] Accordingly, it should be understood that the motor controller should be able to adapt not only to changes in the surgical environment but also to changes in the motor and drivetrain components when using an electrosurgical suturing system. The adaptation of the motor controller and the motor control signal can be generated from comparison data of the motor and / or drivetrain under different conditions or over time. In some non-limiting examples, such data can include operational data from a motor or sensor associated with the drivetrain. Thus, the motor controller can receive first data indicative of the operation of a motor operating under a first condition, receive second data indicative of the operation of a motor operating under a second condition, and adjust the motor control signal based on the difference between the first data and the second data.

[0151] Figure 25 Flowchart 10000 of a method for controlling a motor in an electrosurgical suturing system based on differential measurements of motor and / or drivetrain operation is shown. Thus, the motor controller can receive 10002 first data indicative of the operation of a motor operating under a first condition. Additionally, the motor controller can receive 10004 second data indicative of the operation of a motor operating under a second condition. The motor controller can then adjust 10006 the motor control signal, such as a pulse width modulation (PWM) signal, based on the difference between the first data and the second data.

[0152] In some aspects, the determination of the operation of the motor and the motor gear reducer assembly can be obtained from a first rotary encoder attached to the motor drive shaft and a second rotary encoder attached to the motor gear reducer assembly. In some aspects, the motor controller can receive first data including first rotational position data from a first rotational motion encoder mechanically associated with the shaft of the motor and first rotational position data from a second rotational motion encoder mechanically associated with the output of the motor gear reducer assembly. In some aspects, the motor controller can receive second data including second rotational position data from the first rotational motion encoder and second rotational position data from the second rotational motion encoder. The speeds of the motor drive shaft and the motor gear reducer assembly can be measured from the respective encoders based on the change over time of the position outputs of the encoders. Thus, the motor controller can receive first data including one or more of first motor torque data or first motor speed data, and the second data indicative of the operation of the motor can include one or more of second motor torque data or second motor speed data.

[0153] Alternatively, the motor controller may receive first data including one or more of first motor gear reducer assembly torque data or first motor gear reducer assembly speed data, and second data indicative of the operation of the motor gear reducer assembly may include one or more of second motor gear reducer assembly torque data or second motor gear reducer assembly speed data. Thus, adjusting the motor control signal based on the difference between the first data and the second data may include adjusting the motor control signal based on the difference between first rotational position data from a first rotational encoder and first rotational position data from a second rotational encoder, or based on the difference between second rotational position data from the first rotational encoder and second rotational position data from the second rotational encoder.

[0154] The speed of the motor drive shaft and the motor gear reducer assembly should be related to the gear reduction ratio of the gear reducer assembly under no-load conditions. This can provide no-load, maximum speed, minimum torque conditions. Under no-load conditions, the output of the motor drive shaft and the output of the motor gear reducer assembly should be in phase with the motor control signal. However, as the load increases, the output of the motor drive shaft or the output of the motor gear reducer assembly may be phase-shifted relative to the motor control signal. Thus, the measured speed signal from either rotational encoder may deviate from no-load conditions. Accordingly, in some aspects, first data indicative of the operation of a motor operating under a first condition may include first data indicative of the operation of the motor under mechanically no-load conditions, and second data indicative of the operation of a motor operating under a second condition may include second data indicative of the operation of the motor under mechanically loaded conditions.

[0155] Similarly, first data indicative of the operation of a motor gear reducer assembly operating under a first condition may include first data indicative of the operation of the motor gear reducer assembly under mechanically no-load conditions, and second data indicative of the operation of a motor gear reducer assembly operating under a second condition may include second data indicative of the operation of the motor gear reducer assembly under mechanically loaded conditions. Thus, the operation of the motor and / or the motor gear reducer assembly between mechanically no-load and mechanically loaded states can be compared.

[0156] The output speed of the motor gear reducer assembly may be slowed at a higher rate than the phase of the motor speed signal. As mechanical wear increases, the motor recoil due to gear tightening may increase. The increased recoil may also cause a reduction in the speed of the motor gear reducer assembly. Thus, a comparison of motor encoder data with encoder data from the motor gear reducer assembly can be used to estimate the output gear response over time, such as speed or torque. The recoil can be measured under various load conditions, including under no-load conditions and during motor stall conditions.

[0157] In other aspects, comparison of motor characteristics under different conditions can include measurements of current / power drawn from each motor, motor temperature, motor acceleration / deceleration rate, and / or back electromotive force (EMF). These metrics can also be used to characterize changes in motor operation, including but not limited to output speed or torque.

[0158] In another aspect, physical measurements related to drivetrain components can also be used to determine changes in the operation of the motor and / or motor reducer assembly. The comparison can consist of physical displacement, velocity, or position loss, and component recoil associated with one or more components of the drivetrain. For example, drivetrain operation can include positioning components of the drivetrain under known reset or reconfiguration conditions. In one aspect, a drivetrain configured to actuate a tissue cutting blade can have a reset position where the tissue cutting blade is in a fully retracted position (the most proximal position). In another aspect, a drivetrain configured to rotate an end effector about an articulation joint can have a reset position where the longitudinal axis of the end effector is aligned with the longitudinal axis of the shaft assembly (at an angle of approximately 180 degrees between the longitudinal axis of the end effector and the longitudinal axis of the shaft assembly). In another example, data obtained over time from associated position sensors can be used to make measurements of the angular movement of the articulation joint, the rate of change of the angular movement of the articulation joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade. Thus, first data indicative of the operation of a motor operating under a first condition can include first data indicative of one or more of the angular movement of the articulation joint, the rate of change of the angular movement of the articulation joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade, and second data indicative of the operation of a motor operating under a second condition can include one or more of the angular movement of the articulation joint, the rate of change of the angular movement of the articulation joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade. These data can allow the motor controller to track changes in those parameters when using an electrosurgical suturing system. In a system where the same motor is used to drive two different drivetrains (e.g., a tissue cutting drivetrain and an articulation drivetrain), the switching position that positions the first drivetrain to the reset position before allowing the mechanical switch to engage the second drivetrain can be used to monitor the "starting position" over time. Using these data, the motor controller can generate motor control signals for motor speed and motor rotational position that compensate for changes in the system over time.

[0159] As disclosed above, changes in data associated with the use of an electrosurgical system can be used by a motor controller to update or alter algorithms used to control the operation of a motor consistent with a gear reducer assembly. Additional data not associated with the active use of the device can also be incorporated into the motor controller algorithm regarding the history of the device prior to deployment. Knowing the age of the device, shipping and storage conditions, and the total operating time of components can all add valuable information to the system. Adjusting the motor control signal based on such initial conditions can standardize the use of the electrosurgical system over time and between devices. Thus, standardization of device operation will keep surgical outcomes more consistent and predictable.

[0160] In one aspect, first data received by the motor controller indicative of the operation of the motor under a first condition can include data indicative of the operation of the motor at initial manufacture. Second data received by the motor controller indicative of the operation of the motor under a second condition can include data indicative of the operation of the motor at some time after initial manufacture. Non-limiting examples of data indicative of the operation of the motor at some time after initial manufacture can include data obtained regarding the time the electrosurgical system was in a stored state, the total use time of the electrosurgical system, the time between actuations of the tissue cutting blade, the time between rotations about the articulation joint, the total operating time between firings of the tissue cutting blade, the number of firings of the tissue cutting blade, the total time since construction, and / or the total number of uses of the electrosurgical system.

[0161] Data indicative of the operation of the motor at initial manufacture can include any relevant electrical or mechanical data associated with that operation. Such data can include, but is not limited to, the starting current of the motor, the starting acceleration of the motor, the speed of the motor under no-load conditions, the motor operating time for full actuation of the tissue cutting blade in the distal direction, the motor operating time for full actuation of the tissue cutting blade in the proximal direction, the motor operating time for full actuation of the articulation joint in a first motion (clockwise), the motor operating time for full actuation of the articulation joint in a second motion (counterclockwise), and the motor temperature under operation. Accordingly, the motor control signal can be adjusted based on the difference between the operation of the motor at initial manufacture and the operation of the motor at a time after initial manufacture.

[0162] Data indicative of the operation of the motor at initial manufacture can be generated by performing a calibration sequence after the electrosurgical suture system is fully assembled. For statistical purposes, multiple calibration sequences can be run after initial manufacture, and appropriate statistical data, such as mean and standard deviation values, can be retained. Data indicative of the operation of the motor at initial manufacture can be stored in a memory device of the electrosurgical suture device or can be accessed by a motor controller of the electrosurgical suture device via a network connection to any one or more of a surgical hub or a cloud-based networking system.

[0163] Data associated with the electrosurgical suture system immediately after manufacture can be used as a baseline against which the operation of the electrosurgical suture system can be compared. In this way, operational degradation can be measured and the control algorithm of the motor controller can be adjusted to compensate for the degradation. Adjustment of the control algorithm can include adjustment of control thresholds for the operation of the motor and / or motor gear reducer assembly, such as motor current, motor voltage, or motor and / or motor gear reducer assembly speed thresholds. Algorithms designed to adjust pulse width modulation (PWM) motor control signals can also be adjusted to compensate for non-use conditions.

[0164] As disclosed above, a comparison can be made between the operation of the electrosurgical suture system immediately after manufacture and at some time after manufacture. The time after manufacture can include the time after the electrosurgical suture system has been used for a predetermined number of cases. The time after manufacture can include the time when the user receives the electrosurgical suture system. Additionally, initial operation data from the manufacture of the motor and / or motor gear reducer assembly can be obtained separately. In some aspects, the time after manufacture of the motor and / or motor gear reducer assembly can include the initial use time of the electrosurgical suture system. Thus, the motor controller can receive initial manufacture motor and gear reducer assembly characteristic data from the manufacturer. The motor controller can then receive operational motor and gear reducer assembly data during the initial use of the electrosurgical suture system. An algorithm in the motor controller for controlling motor operation can then adjust one or more parameters of the motor control signal based on a comparison between the initial manufacture motor and gear reducer assembly characteristic data and the operational motor and gear reducer assembly data during the initial use of the electrosurgical suture system. In certain aspects, the adjustment is based on the difference between the initial manufacture motor and gear reducer assembly characteristic data and the operational motor and gear reducer assembly data during the initial use of the electrosurgical suture system.

[0165] A method of adjusting the operation of the motor and / or motor gear reducer assembly is in Figure 26is shown in the flowchart 10010. Thus, the motor controller can receive 10012 initial manufacturing motor and gear reducer assembly characteristic data from the manufacturer. The motor controller can then receive 10014 operating motor and gear reducer assembly data during the initial use of the electrosurgical suture system. The motor controller can then adjust 10016 the parameters of the motor control signal based on the difference between the initial manufacturing motor and gear reducer assembly characteristic data and the operating motor and gear reducer assembly data during the initial use of the electrosurgical suture system.

[0166] In some aspects of the method, receiving the initial manufacturing motor and gear reducer assembly characteristic data can include receiving one or more of initial motor speed data, initial motor torque data, initial gear reducer assembly torque transmission data, initial motor temperature data, or initial gear reducer assembly temperature data.

[0167] In some aspects of the method, receiving the operating motor and gear reducer assembly data during the initial use of the electrosurgical suture system can include receiving first-use motor back electromotive force (EMF) data, first-use motor temperature data, or first-use gear reducer assembly temperature data.

[0168] In some aspects, the method can further include the motor controller receiving initial manufacturing motor and gear reducer assembly acceptance data.

[0169] In some aspects, the method can further include the motor controller adjusting one or more parameters of the motor control signal based on the difference between the initial manufacturing motor and gear reducer assembly acceptance data and the operating motor and gear reducer assembly data during the initial use of the electrosurgical suture system.

[0170] In some aspects of the method, adjusting one or more parameters of the motor control signal includes adjusting one or more of the maximum motor current, motor voltage, PID controller parameters, timing parameters, motor speed, or threshold step, or the motor control signal waveform.

[0171] Data received from the motor and / or motor gear reducer assembly manufacturer can be stored in the non-volatile memory of the electrosurgical suture system after the data has been determined. Alternatively, the data received from the manufacturer can be shipped as a memory device (such as a flash drive) for the user to install in the electrosurgical suture system. In another alternative, the data received from the manufacturer can be accessed by the electrosurgical suture system via a computer network (such as via a cloud-based computing system) or via a direct connection to a server controlled by the motor and / or motor gear reducer assembly manufacturer. As disclosed above, the initial data from the manufacturer can be used as a baseline for similar data obtained during or after using the electrosurgical suture system.

[0172] In addition to data associated with the operation of the motor, the initial motor and / or motor gear reducer assembly manufacturing data may also include data associated with the gear reducer assembly. Speed, torque, and operating temperature data may also be obtained separately for the gear reducer assembly. The operating temperature distribution data for the gear reducer assembly may overlap the operating temperature distribution data for the equivalent motor heating, speed, and torque data to determine specific critical points. Non-concentric motor shaft problems may be detected, which may help determine uneven rotor alignment in the motor. Additionally, changes in motor torque over time may be identified, and parameters of the motor control signal algorithm may be adjusted to compensate for such changes. Additional data that may be obtained from the initial motor manufacturer may relate to motor winding variations, the magnetic strength of the permanent magnets used in the motor, and the brush / rotor contact area of a DC brushed motor.

[0173] The initial temperature of the motor assembly (either the motor alone or in combination with the gear reducer assembly) may be used to determine the initial performance characteristics of the electrosurgical suturing system. The initial motor / heating transfer function may be used to better predict future motor performance. In addition to motor back-EMF measurements, other current and / or voltage measurements may also be obtained for brushed or brushless DC motors. As disclosed above, the electrosurgical suturing system may be used with a plurality of interchangeable surgical shaft assemblies. By including manufacturer data for both the motor and the motor gear reducer assembly, the motor control algorithm may be adjusted to different shaft assemblies, thereby "standardizing" or matching the motor operation across all interchangeable shaft assemblies.

[0174] In some aspects, the initial motor and motor gear reducer assembly data may allow for the matching of a higher performance motor with a slightly lower performance motor gear reducer assembly. In this way, the performance error range of the motor gear reducer assembly may be kept narrower and the likelihood of component scrap minimized. More components that would otherwise be scrapped under normal conditions may thus be used.

[0175] As disclosed above, it may be useful to control component performance characteristics to standardize the overall system performance output of a plurality of interchangeable shaft assemblies. In a non-limiting example, a motor and a motor gear reducer assembly may undergo an acceptance test after final assembly to verify that the assembly meets performance goals. Both the motor and the motor gear reducer assembly may have target acceptance values for a normal system, including tolerance ranges for minimum and maximum outputs. The target nominal performance of the motor and the motor gear reducer assembly may be affected by component tolerances and / or the assembly, which may affect drive variations in terms of efficiency and performance. Currently, all motor and motor gear reducer assemblies that meet the target performance tolerances can be assembled together for the final system. As an alternative, matching the performance of the motor with the performance of the motor gear reducer assembly can drive the target output of the system to a defined target and minimize variations in the overall system. Thus, coupling a motor with 80% efficiency to a motor gear reducer assembly with 70% efficiency will result in a total system efficiency of 75%. Alternatively, coupling a motor with 70% efficiency to a motor gear reducer assembly with 85% efficiency has an efficiency of 75%. Although the components differ independently in their respective efficiencies, the combination of the components with the electrosurgical suture system will balance the final output and the drive for devices with the same final output. In this way, appropriately combining the motor and the motor gear reducer assembly can result in a reduction in variations between the device and the performance output.

[0176] In some aspects, the initial manufacturing data of the motor and the motor gear reducer assembly can be used as an input for setting and adjusting the limits of the motor control signal algorithm. In a non-limiting example, the manufacturer may provide acceptance data for the motor and the motor gear reducer assembly after final assembly to verify that the motor assembly meets performance goals. This data can be stored on the component via RFID or embedded in the cloud based on the serial number. During the manufacturing / assembly of the electrosurgical suture system, this data can be stored in the motor controller and read by the motor controller to set the various operating limits of the device. For example, the motor may have different outputs for voltage / temperature determined at the component level. The motor control algorithm can adapt to those limits for a specific electrosurgical suture system configuration to operate the algorithm only within a predetermined motor operating range. Additionally, the motor gear reducer assembly may have different efficiencies at different speeds. The motor gear reducer assembly acceptance data can be used as an input to drive the algorithm to operate at the highest speed configured for the specific powered surgical suture system.

[0177] In the operation of various DC motors, the motor operation can be controlled by a pulse width modulation (PWM) system. The PWM system generates a signal based on a base frequency defined by the period of time during which current pulses are supplied to the motor. Each current pulse occurs over some portion of the period of time and can represent any percentage of the period of time from 0% (no current supplied during the period of time) to 100% (current supplied during the entire period of time). The speed of the motor can depend on the portion of the period of time during which current is supplied, and thus the motor speed is pulse width modulated by the current over the period of time.

[0178] Typically, the PWM base frequency remains constant throughout the motor control sequence. However, additional tuning of the motor operation can be obtained by changing not only the pulse width but also the base frequency of the PWM system. Adapting the frequency of the PWM to vary the motor output can improve the active control of the dynamic inertia of the driveline by transitioning between two or more different operating states. The ability to adjust the motor control algorithm after initial programming can be useful in intelligent surgical devices. In some operating states, the motor controller processor can operate at a fixed frequency and output command information based on that fixed frequency. An independent system with greater processing power and operating at a faster speed can provide additional updated information for the command signal from the processor. By combining or adapting the two signals, a more desirable signal can be generated to command the motor controller.

[0179] In one aspect, the PWM system can operate in at least two modes. In a first mode, the PWM motor control signal can drive the system in only a single direction at a single PWM base frequency. In a second mode, the PWM motor control signal can operate at a frequency below the base frequency, which can cause the system to alternate between driving the motor and associated driveline in the drive direction and braking in the direction opposite to friction. This second mode enables slower controlled motion in systems using brushless motors or in systems where gears in a gear reducer assembly vary significantly in response as they age, as their operating temperature increases, or with use. A reduction in the base frequency of the PWM system can enable the motor controller to better control slower speeds and stops.

[0180] In one example, an electrosurgical suturing system can be clamped on a large bundle of tissue. Initially, the motor controller can supply a constant power to the tissue blade drive system to increase its overall inertia. Doing so can ensure the necessary performance to start cutting / suturing the tissue. During the initial part of the drive, the PWM base frequency can be increased to have greater resolution when there are small changes in the tissue blade drivetrain. These changes can be a function of both the tissue held in the jaws and the tissue blade drivetrain. Once the tissue blade drivetrain has established an initial nominal speed, the PWM frequency can be decreased for most of the remaining drive distance. The PWM frequency will only be quickly increased again for finer motion control when an operating anomaly is detected, such as a sudden increase in tissue thickness that may affect the cutting speed. At the end of the tissue cutting cycle, the PWM algorithm can be adjusted again when the blade stops traveling. This adjustment of the PWM frequency during a full cutting stroke operation can ensure full blade extension while also ensuring that the blade does not overtravel at the end of the cut.

[0181] The adaptation of the PWM base frequency to the operating conditions is a time-based method for modifying the interaction between the tissue blade drivetrain and the tissue. By increasing the PWM signal base frequency of the motor coupled to the tissue blade drivetrain, the tissue will not have time to relax or react to the tissue cutting process. By slowing down the PWM signal base frequency, the motor controller can provide the tissue with additional time to react or relax during the "off" cycle of the PWM.

[0182] Figure 27 Flowchart 10020 of a method for adjusting motor and / or drivetrain operation based on changes in the PWM base frequency is presented. Thus, the motor controller can control (10022) the pulse width modulated motor control signal to the motor. The motor controller can receive (10024) data related to the interaction between the tissue cutting blade and the tissue held by the anvil of the electrosurgical suturing device. In one example, the data can relate to the current required to maintain the speed of the tissue cutting blade as it cuts the tissue. In another example, the data can relate to the time to traverse a given distance when the tissue cutting blade cuts the tissue. In an alternative example, the data can relate to the change in the speed of the tissue cutting blade when it first starts cutting the tissue. In yet another example, the data can relate to the change in the tissue cutting speed when the tissue cutting blade finishes cutting the tissue and continues to move after encountering a tissue load. The motor controller can then adjust (10026) the frequency of the pulse width modulated motor control signal based on the data related to the interaction between the tissue cutting blade and the tissue held by the anvil.

[0183] In one aspect, adjusting the frequency of the pulse width modulated motor control signal includes maintaining a first frequency of the pulse width modulated motor control signal when the tissue cutting blade is not in contact with the tissue.

[0184] In another aspect, adjusting the frequency of the pulse width modulated motor control signal can include changing the frequency of the pulse width modulated motor control signal between a first frequency and a second frequency. For example, the motor controller can alternately drive the tissue cutting blade into the tissue at the first frequency and drive the tissue cutting blade away from the tissue at the second frequency. In another example, the tissue cutting blade can be driven at the first frequency when the tissue cutting blade first contacts the tissue and can be driven at the second frequency after the tissue cutting blade first contacts the tissue. In some examples, the second frequency can be less than the first frequency.

[0185] Aspects of the subject matter described herein are set forth in the following examples.

[0186] Example 1 - A method of controlling a motor in an electrosurgical suturing system, wherein the electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulation joint, the motor, a motor power source, a motor gear reduction assembly mechanically coupled to the motor, and a motor controller, the method comprising: receiving, by the motor controller, first data indicative of the operation of the motor operating under a first condition; receiving, by the motor controller, second data indicative of the operation of the motor operating under a second condition; and adjusting, by the motor controller, a motor control signal based on a difference between the first data and the second data.

[0187] Example 2 - The method according to Example 1, wherein receiving the first data indicative of the operation of the motor includes receiving first rotational position data from a first rotational motion encoder mechanically associated with the shaft of the motor and first rotational position data from a second rotational motion encoder mechanically associated with the output of the motor gear reduction assembly, and receiving the second data indicative of the operation of the motor includes receiving second rotational position data from the first rotational motion encoder and second rotational position data from the second rotational motion encoder.

[0188] Example 3 - The method according to Example 1 or 2, wherein receiving the first data indicative of the operation of the motor operating under the first condition includes receiving first data indicative of the operation of the motor under a mechanical no-load condition, and receiving, by the motor controller, the second data indicative of the operation of the motor operating under the second condition includes receiving second data indicative of the operation of the motor under a mechanical load condition.

[0189] Example 4 - The method according to any one of Examples 1 to 3, wherein adjusting the motor control signal by the motor controller based on the difference between the first data and the second data includes adjusting the motor control signal based on the difference between the first rotational position data from the first rotational motion encoder and the first rotational position data from the second rotational motion encoder, or based on the difference between the second rotational position data from the first rotational motion encoder and the second rotational position data from the second rotational motion encoder.

[0190] Example 5 - The method according to any one of Examples 1 to 4, wherein receiving the first data indicating the operation of the motor includes receiving one or more of first motor torque data or first motor speed data, and receiving the second data indicating the operation of the motor includes receiving one or more of second motor torque data or second motor speed data.

[0191] Example 6 - The method according to any one of Examples 1 to 5, wherein receiving the first data indicating the operation of the motor operating under the first condition includes receiving first data indicating one or more of the angular motion of the joint movement joint, the rate of change of the angular motion of the joint movement joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade, and receiving, by the motor controller, the second data indicating the operation of the motor operating under the second condition includes receiving second data indicating one or more of the angular motion of the joint movement joint, the rate of change of the angular motion of the joint movement joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade.

[0192] Example 7 - The method according to any one of Examples 1 to 6, wherein receiving the first data indicating the operation of the motor operating under the first condition includes receiving first data indicating the operation of the motor at the time of initial manufacture, and receiving, by the motor controller, the second data indicating the operation of the motor operating under the second condition includes receiving second data indicating the operation of the motor at a time after initial manufacture.

[0193] Example 8 - The method according to any one of Examples 1 to 7, wherein receiving the second data indicative of the operation of the motor at the time after initial manufacture includes receiving second data indicative of the operation of the motor in any one or more of the following situations: the time when the electrosurgical suturing system is in a storage state, the total usage time of the electrosurgical suturing system, the time between actuations of the tissue cutting blade, the time between rotations about the articulating joint, or the total number of uses of the electrosurgical suturing system.

[0194] Example 9 - The method according to any one of Examples 1 to 8, wherein adjusting the motor control signal based on the difference between the first data and the second data includes adjusting the motor control signal based on the difference between the operation of the motor at the time of initial manufacture and the operation of the motor at the time after initial manufacture.

[0195] Example 10 - A method of controlling a motor in an electrosurgical suturing system, wherein the electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller, the method comprising: receiving, by the motor controller, initial manufacture motor and gear reducer assembly characteristic data from a manufacturer; receiving, by the motor controller, operation motor and gear reducer assembly data during an initial use of the electrosurgical suturing system; and adjusting, by the motor controller, one or more parameters of a motor control signal based on a difference between the initial manufacture motor and gear reducer assembly characteristic data and the operation motor and gear reducer assembly data during the initial use of the electrosurgical suturing system.

[0196] Example 11 - The method according to Example 10, wherein receiving the initial manufacture motor and gear reducer assembly characteristic data includes receiving one or more of initial motor speed data, initial motor torque data, initial gear reducer assembly torque transmission data, initial motor temperature data, or initial gear reducer assembly temperature data.

[0197] Example 12 - The method according to Example 10 or 11, wherein receiving the operation motor and gear reducer assembly data during the initial use of the electrosurgical suturing system includes receiving first use motor back electromotive force (EMF) data, first use motor temperature data, or first use gear reducer assembly temperature data.

[0198] Example 13 - The method according to any one of Examples 10 to 12, the method further comprising receiving, by the motor controller, initial manufacture motor and gear reducer assembly acceptance data.

[0199] Example 14 - The method according to any one of Examples 10 to 13, the method further comprising adjusting, by the motor controller, one or more parameters of the motor control signal based on a difference between the initial manufactured motor and gear reducer assembly acceptance data and the operating motor and gear reducer assembly data during the initial use of the electrosurgical suturing system.

[0200] Example 15 - The method according to any one of Examples 10 to 14, wherein adjusting one or more parameters of the motor control signal comprises adjusting one or more of a maximum motor current, a motor voltage, PID controller parameters, timing parameters, a motor speed, or a threshold step, or a motor control signal waveform.

[0201] Example 16 - A method of controlling a motor in an electrosurgical suturing system, wherein the electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller, wherein the motor is configured to actuate the tissue cutting blade, the method comprising: controlling, by the motor controller, a pulse width modulation motor control signal to the motor; receiving, by the motor controller, data regarding an interaction between the tissue cutting blade and tissue clamped by the anvil; and adjusting, by the motor controller, a frequency of the pulse width modulation motor control signal based on the data regarding the interaction between the tissue cutting blade and the tissue clamped by the anvil.

[0202] Example 17 - The method according to Example 16, wherein adjusting the frequency of the pulse width modulation motor control signal comprises maintaining a first frequency of the pulse width modulation motor control signal when the tissue cutting blade is not in contact with the tissue.

[0203] Example 18 - The method according to Example 16 or 17, wherein adjusting the frequency of the pulse width modulation motor control signal by the motor controller comprises changing the frequency of the pulse width modulation motor control signal between a first frequency and a second frequency.

[0204] Example 19 - The method according to any one of Examples 16 to 18, wherein changing the frequency of the pulse width modulation motor control signal between the first frequency and the second frequency comprises alternately driving the tissue cutting blade into the tissue at the first frequency and driving the tissue cutting blade away from the tissue at the second frequency.

[0205] Example 20 - The method according to any one of Examples 16 to 19, wherein varying the frequency of the pulse width modulated motor control signal between the first frequency and the second frequency comprises driving the tissue cutting blade at the first frequency when the tissue cutting blade first contacts the tissue and driving the tissue cutting blade at the second frequency after the tissue cutting blade first contacts the tissue, wherein the second frequency is less than the first frequency.

[0206] Many of the surgical instrument systems described herein are actuated by an electric motor; however, the surgical instrument systems described herein may be actuated in any suitable manner. In various cases, for example, the surgical instrument systems described herein may be actuated by a manually operated trigger. In certain cases, the motors disclosed herein may comprise part or parts of a robotic control system. Additionally, any end effector and / or tool assembly disclosed herein may be used with a robotic surgical instrument system. For example, U.S. Patent Application Serial No. 13 / 118,241 (now U.S. Patent 9,072,535), entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS", discloses several examples of robotic surgical instrument systems in more detail and is incorporated herein by reference in its entirety.

[0207] The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not limited thereto. For example, various embodiments are envisioned for deploying fasteners other than staples such as clamps or tacks. Additionally, various embodiments are envisioned that utilize any suitable means for sealing tissue. For example, an end effector according to various embodiments may include electrodes configured to heat and seal tissue. Additionally, for example, an end effector according to certain embodiments may apply vibrational energy to seal tissue.

[0208] Although multiple forms have been illustrated and described, the applicant does not intend to limit or restrict the scope of the appended claims to such details. Many modifications, variations, alterations, substitutions, combinations, and equivalents of these forms can be made without departing from the scope of the present disclosure, and many of these will be envisioned by those skilled in the art. Additionally, alternatively, the structure of each element associated with the described forms can be described as a means for providing the function performed by the element. Further, in cases where materials for certain components are disclosed, other materials can also be used. Accordingly, it should be understood that the foregoing detailed description and the appended claims are intended to cover all such modifications, combinations, and variations that fall within the scope of the forms disclosed by the present invention. The appended claims are intended to cover all such modifications, variations, alterations, substitutions, modifications, and equivalents.

[0209] The foregoing detailed description has set forth various forms of apparatuses and / or methods by use of block diagrams, flowcharts, and / or examples. As long as such block diagrams, flowcharts, and / or examples contain one or more functions and / or operations, those skilled in the art will understand that each function and / or operation within such block diagrams, flowcharts, and / or examples can be implemented, individually and / or jointly, by a variety of hardware, software, firmware, or in fact any combination thereof. Those skilled in the art will recognize that some aspects of the forms disclosed herein can be equivalently implemented, in whole or in part, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or as in fact any combination thereof in an integrated circuit, and that designing the circuitry and / or writing the code for the software and / or hardware will be within the skill of those in the art in light of the present disclosure. Additionally, those skilled in the art will understand that the mechanisms of the subject matter described herein can be distributed as one or more program products in a variety of forms, and that the illustrative forms of the subject matter described herein apply regardless of the particular type of signal-bearing medium used to actually effect the distribution.

[0210] Instructions for programming logic to perform the various disclosed aspects can be stored in a memory within the system, such as dynamic random access memory (DRAM), cache, flash memory, or other memory. Additionally, the instructions can be distributed via a network or by other computer-readable media. Thus, machine-readable media can include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer), but are not limited to floppy disks, optical disks, compact disc read-only memory (CD-ROM), and magneto-optical disks, read-only memory (ROM), random access memory (RAM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), magnetic or optical cards, flash memory, or tangible, machine-readable storage devices used to transmit information over the Internet via electrical, optical, acoustic, or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.). Thus, non-transitory computer-readable media includes any type of tangible machine-readable media suitable for storing or transmitting electronic instructions or information in a form readable by a machine (e.g., a computer).

[0211] As used in any aspect herein, the term "control circuit" can refer to, for example, hardwired circuitry, programmable circuitry (e.g., a computer processor that includes one or more individual instruction processing cores, processing units, processors, microcontrollers, microcontroller units, controllers, digital signal processors (DSPs), programmable logic devices (PLDs), programmable logic arrays (PLAs), field programmable gate arrays (FPGAs)), state machine circuitry, firmware that stores instructions executed by programmable circuitry, and any combination thereof. The control circuit can be implemented collectively or individually as a circuit that forms part of a larger system, such as an integrated circuit (IC), an application specific integrated circuit (ASIC), a system on a chip (SoC), a desktop computer, a laptop computer, a tablet computer, a server, a smart phone, etc. Thus, as used herein, "control circuit" includes, but is not limited to, an electronic circuit having at least one discrete circuit, an electronic circuit having at least one integrated circuit, an electronic circuit having at least one application specific integrated circuit, an electronic circuit forming a general purpose computing device configured by a computer program (such as a general purpose computer configured by a computer program that at least partially implements the methods and / or devices described herein, or a microprocessor configured by a computer program that at least partially implements the methods and / or devices described herein), an electronic circuit forming a memory device (such as forming a random access memory), and / or an electronic circuit forming a communication device (such as a modem, a communication switch, or an optoelectronic device). Those skilled in the art will recognize that the subject matter described herein can be implemented in analog or digital fashion or some combination thereof.

[0212] As used in one or more aspects of the present disclosure, a microcontroller generally may include a memory and a microprocessor (“processor”) operatively coupled to the memory. The processor may control a motor driver circuit, which generally is used to control, for example, the position and rate of a motor. In some cases, the processor may signal the motor driver to, for example, stop and / or disable the motor. In some cases, the microcontroller may be, for example, the LM4F230H5QR available from Texas Instruments. In at least one example, the Texas Instruments LM4F230H5QR is a chip-on-memory with an ARM Cortex-M4F processor core including up to 256KB of single-cycle flash memory or other non-volatile memory at up to 40MHz, a prefetch buffer for performance improvement above 40MHz, 32KB of single-cycle serial random access memory (SRAM), a built-in read-only memory (ROM) loaded with software, 2KB of electrically erasable programmable read-only memory (EEPROM), one or more pulse-width modulation (PWM) modules, one or more quadrature encoder input (QEI) analogs, one or more 12-bit analog-to-digital converters (ADCs) with 12 analog input channels, and other feature structures readily available in the product data sheet.

[0213] It should be understood that the term processor as used herein includes any suitable microprocessor, or another basic computing device that combines the functionality of a central processing unit (CPU) of a computer on one integrated circuit or at most a few integrated circuits. A processor is a multipurpose programmable device that receives digital data as input, processes the input according to instructions stored in its memory, and then provides results as output. Since a processor has internal memory, it is an example of sequential digital logic. The operations of a processor are on numbers and symbols represented in the binary number system.

[0214] In at least one case, the processor may be any single-core or multi-core processor, such as those known commercially as ARM Cortex produced by Texas Instruments. However, other suitable alternatives of microcontrollers and security processors may be employed without limitation.

[0215] As used in any aspect herein, the term “logic” may refer to an application, software, firmware, and / or circuitry configured to perform any of the foregoing operations. Software may be embodied as a software package, code, instructions, instruction set, and / or data recorded on a non-transitory computer-readable storage medium. Firmware may be embodied as code, instructions, or instruction set and / or data hard-coded (e.g., non-volatile) in a memory device.

[0216] As used in any aspect of this disclosure, the terms "component", "system", "module", etc. can refer to a computer-related entity, hardware, a combination of hardware and software, software, or software in execution.

[0217] As used in any aspect of this disclosure, an "algorithm" refers to an ordered sequence of steps that result in a desired outcome, where a "step" refers to the manipulation of physical quantities and / or logical states, which may (but need not) take the form of electrical or magnetic signals that can be stored, transferred, combined, compared, and otherwise manipulated. These signals are commonly referred to as, for example, bits, values, elements, symbols, characters, terms, numbers, etc. These and similar terms can be associated with appropriate physical quantities and are merely convenient labels applied to these quantities and / or states.

[0218] Various apparatuses, tools, hubs, devices, and / or systems in accordance with the present disclosure may be capable of communicating with each other using a selected packet-switched network communication protocol. An exemplary communication protocol may include an Ethernet communication protocol that may be capable of allowing communication using the Transmission Control Protocol / Internet Protocol (TCP / IP). The Ethernet protocol may conform to or be compatible with the Ethernet standard titled "IEEE 802.3 Standard" published by the Institute of Electrical and Electronics Engineers (IEEE) in December 2008 and / or later versions of this standard. Alternatively or additionally, the communication devices may be capable of communicating with each other using the X.25 communication protocol. The X.25 communication protocol may conform to or be compatible with the standards published by the International Telecommunication Union Telecommunication Standardization Sector (ITU-T). Alternatively or additionally, the communication devices may be capable of communicating with each other using the Frame Relay communication protocol. The Frame Relay communication protocol may conform to or be compatible with the standards published by the Consultative Committee for International Telegraph and Telephone (CCITT) and / or the American National Standards Institute (ANSI). Alternatively or additionally, the transceivers may be capable of communicating with each other using the Asynchronous Transfer Mode (ATM) communication protocol. The ATM communication protocol may conform to or be compatible with the ATM standard titled "ATM-MPLS Network Interworking 2.0" published by the ATM Forum in August 2001 and / or later versions of this standard. Of course, different and / or later-developed connection-oriented network communication protocols are also contemplated herein.

[0219] As described herein, one or more motor assemblies employ one or more electric motors. In various forms, the electric motor can be, for example, a DC brushed drive motor. In other arrangements, the motor can include a brushless motor, a cordless motor, a synchronous motor, a stepper motor, or any other suitable electric motor. The electric motor can be powered by a power source, which in one form can include a removable power pack. The batteries can each include, for example, lithium ion (“LI”) or another suitable battery. The electric motor can include, for example, a rotatable shaft operably engaged with a gear reducer assembly. In some cases, the voltage polarity provided by the power source can operate the electric motor in a clockwise direction, where the voltage polarity applied to the electric motor by the battery can be reversed to operate the electric motor in a counterclockwise direction. In various aspects, a microcontroller controls the electric motor via a pulse width modulation control signal through a motor driver. The motor driver can be configured to adjust the speed of the electric motor in a clockwise or counterclockwise direction. The motor driver is also configured to switch between multiple operating modes, which include an electronic motor braking mode, a constant speed mode, an electronic clutch mode, and a controlled current activation mode. In the electronic braking mode, the two terminals of the drive motor are shorted, and the generated back EMF cancels the rotation of the electric motor, allowing for faster stopping and greater position accuracy.

[0220] As used in any aspect of this disclosure, wireless transmission (e.g., wireless communication or wireless transmission of data signals) can be implemented by a device that includes one or more transceivers. The transceiver can include, but is not limited to, a cellular modem, a wireless mesh network transceiver, a transceiver, a low power wide area (LPWA) transceiver, and / or a near field communication transceiver (NFC). The device can include a mobile phone, a sensor system (e.g., environmental, location, motion, etc.) and / or a sensor network (wired and / or wireless), a computing system (e.g., a server, a workstation computer, a desktop computer, a laptop computer, a tablet computer (e.g., etc.), an ultraportable computer, an ultra-mobile computer, a netbook computer, and / or a subnotebook computer, etc. or can be configured to communicate with these devices. In at least one aspect of the present disclosure, one of the devices can be a coordinator node.

[0221] The transceiver can be configured to receive serial transmission data from a processor via a corresponding Universal Asynchronous Receiver-Transmitter (UART), modulate the serial transmission data onto an RF carrier to generate a transmitted RF signal, and transmit the transmitted RF signal via a corresponding antenna. The transceiver can be further configured to receive a received RF signal via a corresponding antenna (the received RF signal includes an RF carrier modulated with serial received data), demodulate the received RF signal to extract the serial received data, and provide the serial received data to the corresponding UART for providing to the processor. Each RF signal has an associated carrier frequency and an associated channel bandwidth. The channel bandwidth is associated with the carrier frequency, the transmitted data, and / or the received data. Each RF carrier frequency and channel bandwidth are related to the operating frequency range of the transceiver. Each channel bandwidth is further related to the wireless communication standard and / or protocol that the transceiver can comply with. In other words, each transceiver can correspond to a specific implementation of a selected wireless communication standard and / or protocol, such as IEEE 802.11a / b / g / n for and IEEE 802.15.4 for wireless mesh networks using Zigbee routing.

[0222] Unless otherwise expressly specified in the foregoing disclosure, it is to be understood that in the foregoing disclosure, discussions using terms such as "processing", "estimating", "calculating", "determining", "displaying" refer to the actions and processes of a computer system or similar electronic computing device that manipulates data represented as physical (electronic) quantities within the registers and memories of the computer system and converts it into other data similarly represented as physical quantities within the memories or registers or other such information storage, transmission, or display devices of the computer system.

[0223] One or more components may be referred to herein as "configured to", "configurable to", "operable / operatively", "adapted / adaptable to", "capable of", "conformable / conformed to", etc. Those skilled in the art will recognize that, unless the context dictates otherwise, "configured to" generally can encompass components in an active state and / or components in an inactive state and / or components in a standby state.

[0224] The terms "proximal" and "distal" are used herein relative to a clinician manipulating the handle portion of a 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 should also be understood that, for simplicity and clarity, spatial terms such as "vertical", "horizontal", "up", and "down" may be used herein in conjunction with the drawings. However, the surgical instrument is used in many orientations and positions, and these terms are not restrictive and / or absolute.

[0225] Those skilled in the art will recognize that, generally speaking, the terms used herein, and especially in the appended claims (e.g., the body of the appended claims), are generally intended to be "open" terms (e.g., the term "comprising" should be interpreted as "comprising but not limited to", the term "having" should be interpreted as "having at least", the term "including" should be interpreted as "including but not limited to", etc.). Those skilled in the art should also understand that if a specific number of introduced claim recitations is intended, such intention will be expressly recited in the claim, and in the absence of such recitation, no such intention exists. For example, for the sake of understanding, the following appended claims may contain the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as implying that the introduction of a claim recitation by the indefinite article "a" or "an" limits any particular claim containing such introduced claim recitation to a claim containing only one such recitation, even when the same claim includes the introductory phrase "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should generally be interpreted as meaning "at least one" or "one or more"); this also applies to the use of the definite article for introducing claim recitations.

[0226] In addition, even if a specific number of introduced claim recitations is expressly recited, those skilled in the art should recognize that such recitation should generally be interpreted as meaning at least the recited number (e.g., in the absence of other modifiers, a bare recitation of "two recitations" generally means at least two recitations, or two or more recitations). Moreover, in those cases where a convention similar to "at least one of A, B, and C, etc." is used, generally speaking, such construction is intended to have the meaning that those skilled in the art will understand the convention (e.g., "a system having at least one of A, B, and C" will include but not be limited to a system having only A, only B, only C, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those cases where a convention similar to "at least one of A, B, or C, etc." is used, generally speaking, such construction is intended to have the meaning that those skilled in the art will understand the convention (e.g., "a system having at least one of A, B, or C" should include but not be limited to a system having only A, only B, only C, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Those skilled in the art should also understand that, generally, unless the context otherwise indicates, disjunctive words and / or phrases presenting two or more alternative terms, whether in the detailed description, claims, or drawings, should be understood to cover the possibility of including one of the terms, any one of the terms, or both terms. For example, the phrase "A or B" will generally be understood to include the possibility of "A" or "B" or "A and B".

[0227] For the appended claims, those skilled in the art will understand that the operations recited therein can generally be performed in any order. Additionally, although various operation flowcharts are presented in one or more sequences, it should be understood that the various operations can be performed in other orders different from the shown order, or the various operations can be performed simultaneously. Unless otherwise specified in the context, examples of such alternative orderings may include overlapping, interleaving, interrupting, reordering, incremental, preparatory, supplementary, simultaneous, reverse, or other altered orderings. Furthermore, unless otherwise specified in the context, terms such as "responsive to", "associated with", or other past tense adjectives generally do not intend to exclude such variations.

[0228] It is worth noting that any reference to "an aspect", "one aspect", "an example", "one example" means that the specific feature, structure, or characteristic described in connection with that aspect is included in at least one aspect. Thus, the phrases "in an aspect", "in one aspect", "in an example", "in one example" that appear at various places throughout the specification do not necessarily all refer to the same aspect. Additionally, the specific features, structures, or characteristics can be combined in any suitable manner in one or more aspects.

[0229] In this specification, unless otherwise indicated, the terms "about" or "approximately" as used in this disclosure refer to an acceptable error of a particular value as determined by a person of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain embodiments, the term "about" or "approximately" refers to within 1, 2, 3, or 4 standard deviations. In certain embodiments, the term "about" or "approximately" refers to within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

[0230] In this specification, unless otherwise indicated, all numerical parameters should be understood in all cases to be prefaced by the term "about" or to be modified by the term "about", where the numerical parameters have the inherent variability characteristics of the underlying measurement techniques used to determine the parameter values. To the lowest extent and without attempting to limit the application of the doctrine of equivalents to the scope of the claims, at least each numerical parameter described herein should be interpreted in accordance with the significant digits reported and by applying ordinary rounding techniques.

[0231] Any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, the range “1 to 10” includes all sub-ranges between the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. Further, all ranges recited herein include the endpoints of the recited range. For example, the range “1 to 10” includes the endpoints 1 and 10. Any upper limit value recited in this specification is intended to include all lesser limit values subsumed therein, and any lower limit value recited in this specification is intended to include all greater limit values subsumed therein. Accordingly, the applicant reserves the right to amend this specification (including the claims) to expressly recite any sub-ranges subsumed within the expressly recited range. All such ranges are inherently described in this specification.

[0232] Any patent application, patent, non-patent publication or other public material mentioned in this specification and / or listed in any application data sheet is incorporated herein by reference, provided that the incorporated material is not inconsistent herewith. Accordingly, and to the extent necessary, the disclosure expressly set forth herein supersedes any conflicting material incorporated herein by reference. Any material or portion thereof that is alleged to be incorporated herein by reference but conflicts with the existing definitions, statements or other public material set forth herein will be incorporated only to the extent that there is no conflict between the incorporated material and the existing public material.

[0233] Broadly speaking, numerous beneficial effects resulting from the adoption of the concepts described herein have been described. For purposes of illustration and description, one or more forms of the foregoing specific embodiments have been provided. These specific embodiments are not intended to be exhaustive or limiting to the precise forms disclosed of the invention. Modifications or variations to the invention can be made in accordance with the above teachings. The one or more forms selected and described are for purposes of illustrating the principles and practical applications so that the ordinary skilled person in the art can utilize the various forms and various modifications suitable for the particular use contemplated. The claims filed herewith are intended to define the full scope.

Claims

1. A motor controller for controlling a motor in an electrosurgical suturing system, wherein, The electric surgical suture system includes an anvil, a tissue cutting blade, an articulation joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and the motor controller, the motor controller being configured to: Receive first data indicative of the operation of the motor operating under a first condition; receive second data indicative of the operation of the motor operating under a second condition; And Adjust a motor control signal based on a difference between the first data and the second data.

2. The motor controller according to claim 1, wherein, When receiving the first data indicative of the operation of the motor, the motor controller is further configured to receive first rotational position data from a first rotational motion encoder mechanically associated with the shaft of the motor and first rotational position data from a second rotational motion encoder mechanically associated with the output of the motor gear reducer assembly, and wherein, when receiving the second data indicative of the operation of the motor, the motor controller is further configured to receive second rotational position data from the first rotational motion encoder and second rotational position data from the second rotational motion encoder.

3. The motor controller according to claim 1 or claim 2, wherein, When receiving the first data indicative of the operation of the motor operating under the first condition, the motor controller is further configured to receive first data indicative of the operation of the motor under a mechanical no-load condition, and wherein, when receiving the second data indicative of the operation of the motor operating under the second condition, the motor controller is further configured to receive second data indicative of the operation of the motor under a mechanical load condition.

4. The motor controller according to any one of the preceding claims, wherein, When adjusting the motor control signal based on the difference between the first data and the second data, the motor controller is further configured to adjust the motor control signal based on a difference between the first rotational position data from the first rotational motion encoder and the first rotational position data from the second rotational motion encoder, or based on a difference between the second rotational position data from the first rotational motion encoder and the second rotational position data from the second rotational motion encoder.

5. The motor controller according to any one of the preceding claims, wherein, When receiving the first data indicative of the operation of the motor, the motor controller is further configured to receive one or more of first motor torque data or first motor speed data, and Wherein, when receiving the second data indicative of the operation of the motor, the motor controller is further configured to receive one or more of second motor torque data or second motor speed data.

6. The motor controller according to claim 5, wherein, When receiving the first data indicative of the operation of the motor operating under the first condition, the motor controller is further configured to receive first data indicative of one or more of the angular motion of the articulation joint, the rate of change of the angular motion of the articulation joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade, and Wherein, when receiving the second data indicative of the operation of the motor operating under a second condition, the motor controller is further configured to receive second data indicative of one or more of the angular motion of the articulating joint, the rate of change of the angular motion of the articulating joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade.

7. The motor controller according to any one of the preceding claims, wherein, When receiving the first data indicative of the operation of the motor operating under the first condition, the motor controller is configured to receive first data indicative of the operation of the motor at initial manufacture, and Wherein, when receiving the second data indicative of the operation of the motor operating under the second condition, the motor controller is configured to receive second data indicative of the operation of the motor at a time after initial manufacture.

8. The motor controller according to claim 7, wherein, When receiving the second data indicative of the operation of the motor at a time after initial manufacture, the motor controller is configured to receive second data indicative of the operation of the motor in any one or more of the following situations: the time the electrosurgical suturing system is in a stored state, the total usage time of the electrosurgical suturing system, the time between actuations of the tissue cutting blade, the time between rotations about the articulating joint, or the total number of uses of the electrosurgical suturing system.

9. The motor controller according to claim 7 or claim 8, wherein, When adjusting the motor control signal based on the difference between the first data and the second data, the motor controller is configured to adjust the motor control signal based on the difference between the operation of the motor at initial manufacture and the operation of the motor at the time after initial manufacture.

10. A method for controlling a motor in an electrosurgical suturing system, preferably a computer-implemented method, wherein, The electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller, and the method includes: Receiving, by the motor controller, first data indicative of the operation of the motor operating under a first condition; Receiving, by the motor controller, second data indicative of the operation of the motor operating under a second condition; and Adjusting, by the motor controller, a motor control signal based on the difference between the first data and the second data.

11. The method according to claim 10, wherein, Receiving the first data indicative of the operation of the motor includes receiving first rotational position data from a first rotational motion encoder mechanically associated with the shaft of the motor and first rotational position data from a second rotational motion encoder mechanically associated with the output of the motor gear reducer assembly, and Receiving the second data indicative of the operation of the motor includes receiving second rotational position data from the first rotational motion encoder and second rotational position data from the second rotational motion encoder.

12. The method according to claim 10 or claim 11, wherein, The first data received indicating the operation of the motor operating under the first condition includes receiving first data indicating the operation of the motor under a mechanically unloaded condition, and the second data received by the motor controller indicating the operation of the motor operating under the second condition includes receiving second data indicating the operation of the motor under a mechanically loaded condition.

13. The method according to claim 11 or claim 12, wherein, Adjusting the motor control signal by the motor controller based on the difference between the first data and the second data includes adjusting the motor control signal based on the difference between the first rotational position data from the first rotational motion encoder and the first rotational position data from the second rotational motion encoder, or based on the difference between the second rotational position data from the first rotational motion encoder and the second rotational position data from the second rotational motion encoder.

14. The method according to any one of claims 10 to 13, wherein, Receiving the first data indicating the operation of the motor includes receiving one or more of first motor torque data or first motor speed data, and Receiving the second data indicating the operation of the motor includes receiving one or more of second motor torque data or second motor speed data.

15. The method according to claim 14, wherein, The first data received indicating the operation of the motor operating under the first condition includes receiving first data indicating one or more of the angular motion of the articulating joint, the rate of change of the angular motion of the articulating joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade, and The second data received by the motor controller indicating the operation of the motor operating under the second condition includes receiving second data indicating one or more of the angular motion of the articulating joint, the rate of change of the angular motion of the articulating joint, the position of the tissue cutting blade, or the rate of change of the position of the tissue cutting blade.

16. The method according to any one of claims 10 to 15, wherein, The first data received indicating the operation of the motor operating under the first condition includes receiving first data indicating the operation of the motor at initial manufacture, and the second data received by the motor controller indicating the operation of the motor operating under the second condition includes receiving second data indicating the operation of the motor at a time after initial manufacture.

17. The method according to claim 16, wherein, Receiving the second data indicating the operation of the motor at a time after initial manufacture includes receiving second data indicating the operation of the motor in any one or more of the following situations: the time the electrosurgical suturing system is in a stored state, the total usage time of the electrosurgical suturing system, the time between actuations of the tissue cutting blade, the time between rotations about the articulating joint, or the total number of uses of the electrosurgical suturing system.

18. The method according to claim 16, wherein, Adjusting the motor control signal based on the difference between the first data and the second data includes adjusting the motor control signal based on the difference between the operation of the motor at initial manufacture and the operation of the motor at the time after initial manufacture.

19. A motor controller for a motor in an electrosurgical suturing system, wherein, The electric surgical suture system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and the motor controller, wherein the motor controller includes a processor configured to execute the method according to any one of claims 10 to 18.

20. An electrosurgical suturing system, the electrosurgical suturing system comprising an anvil, a tissue cutting blade, an articulating joint, a motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller, wherein, The motor controller includes a processor configured to execute the method according to any one of claims 10 to 18.

21. A computer program product comprising instructions which, when executed by a processor included in a motor controller for a motor in an electrosurgical suturing system, cause the motor controller to perform the method according to any one of claims 10 to 18, wherein, The electric surgical suture system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller.

22. A computer-readable data carrier having stored thereon the computer program product according to claim 21.

23. A motor controller for controlling a motor in an electrosurgical suturing system, wherein, The electric surgical suture system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and the motor controller, the motor controller being configured to: Receive initial manufacturing motor and gear reducer assembly characteristic data; Receive operating motor and gear reducer assembly data during an initial use period of the electric surgical suture system; And Adjust one or more parameters of the motor control signal by the motor controller based on a difference between the initial manufacturing motor and gear reducer assembly characteristic data and the operating motor and gear reducer assembly data during the initial use period of the electric surgical suture system.

24. The motor controller according to claim 23, wherein, When receiving the initial manufacturing motor and gear reducer assembly characteristic data, the motor controller is further configured to receive one or more of initial motor speed data, initial motor torque data, initial gear reducer assembly torque transmission data, initial motor temperature data, or initial gear reducer assembly temperature data.

25. The motor controller according to claim 23 or claim 24, wherein, When receiving the operating motor and gear reducer assembly data during the initial use period of the electric surgical suture system, including receiving first use motor back electromotive force (EMF) data, first use motor temperature data, or first use gear reducer assembly temperature data.

26. The motor controller according to any one of claims 23 to 25, wherein, The motor controller is further configured to receive initial manufacturing motor and gear reducer assembly acceptance data.

27. The motor controller according to claim 26, wherein, The motor controller is further configured to adjust one or more parameters of the motor control signal based on a difference between the initial manufacturing motor and gear reducer assembly acceptance data and the operating motor and gear reducer assembly data during the initial use period of the electric surgical suture system.

28. The motor controller according to any one of claims 23 to 27, wherein, When adjusting one or more parameters of the motor control signal, the motor controller is further configured to adjust one or more of a maximum motor current, a motor voltage, PID controller parameters, timing parameters, a motor speed, or a threshold step, or a motor control signal waveform.

29. A method for controlling a motor in an electrosurgical suturing system, preferably a computer-implemented method, wherein, The electric surgical suture system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller, the method including: Receive, by the motor controller, initial manufacturing motor and gear reducer assembly characteristic data from a manufacturer; Receiving, by the motor controller, operation motor and gear reducer assembly data during an initial use of the electrosurgical suturing system; and Adjusting, by the motor controller, one or more parameters of a motor control signal based on a difference between the initial manufacturing motor and gear reducer assembly characteristic data and the operation motor and gear reducer assembly data during the initial use of the electrosurgical suturing system.

30. The method according to claim 29, wherein, Receiving the initial manufacturing motor and gear reducer assembly characteristic data includes receiving one or more of initial motor speed data, initial motor torque data, initial gear reducer assembly torque transmission data, initial motor temperature data, or initial gear reducer assembly temperature data.

31. The method according to claim 29 or 30, wherein, Receiving the operation motor and gear reducer assembly data during the initial use of the electrosurgical suturing system includes receiving first use motor back electromotive force (EMF) data, first use motor temperature data, or first use gear reducer assembly temperature data.

32. The method according to any one of claims 29 to 31, the method further comprising receiving, by the motor controller, initial manufacturing motor and gear reducer assembly acceptance data.

33. The method according to claim 32, the method further comprising adjusting, by the motor controller, one or more parameters of the motor control signal based on a difference between the initial manufacturing motor and gear reducer assembly acceptance data and the operating motor and gear reducer assembly data during the initial use of the electrosurgical suturing system.

34. The method according to any one of claims 29 to 33, wherein, Adjusting one or more parameters of the motor control signal includes adjusting one or more of a maximum motor current, motor voltage, PID controller parameters, timing parameters, motor speed, or threshold step, or a motor control signal waveform.

35. A motor controller for a motor in an electrosurgical suturing system, wherein, The electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and the motor controller, wherein the motor controller includes a processor configured to execute the method according to any one of claims 29 to 34.

36. An electrosurgical suturing system, the electrosurgical suturing system comprising an anvil, a tissue cutting blade, an articulating joint, a motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller, wherein, The motor controller includes a processor configured to execute the method according to any one of claims 29 to 34.

37. A computer program product comprising instructions which, when executed by a processor included in a motor controller for a motor in an electrosurgical suturing system, cause the motor controller to perform the method according to any one of claims 29 to 34, wherein, The electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller.

38. A computer-readable data carrier having stored thereon the computer program product according to claim 37.

39. A motor controller for controlling a motor in an electrosurgical suturing system, wherein, The electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and the motor controller, wherein the motor is configured to be capable of actuating the tissue cutting blade, and the motor controller is configured to: Control a pulse width modulation motor control signal to the motor; Receive data regarding an interaction between the tissue cutting blade and tissue clamped by the anvil; and Adjust a frequency of the pulse width modulation motor control signal based on the data regarding the interaction between the tissue cutting blade and the tissue clamped by the anvil.

40. The motor controller according to claim 39, wherein,When adjusting the frequency of the pulse width modulation motor control signal, the motor controller is further configured to maintain a first frequency of the pulse width modulation motor control signal when the tissue cutting blade is not in contact with the tissue.

41. The motor controller according to claim 39 or 40, wherein, When adjusting the frequency of the pulse width modulation motor control signal, the motor controller is further configured to change the frequency of the pulse width modulation motor control signal between a first frequency and a second frequency.

42. The motor controller according to claim 41, wherein, When changing the frequency of the pulse width modulated motor control signal between a first frequency and a second frequency, the motor controller is further configured to alternately drive the tissue cutting blade into the tissue at the first frequency and drive the tissue cutting blade away from the tissue at the second frequency.

43. The motor controller according to claim 41, wherein, When changing the frequency of the pulse width modulated motor control signal between the first frequency and the second frequency, the motor controller is further configured to drive the tissue cutting blade at the first frequency when the tissue cutting blade first contacts the tissue and drive the tissue cutting blade at the second frequency after the tissue cutting blade first contacts the tissue, wherein the second frequency is less than the first frequency.

44. A method for controlling a motor in an electrosurgical suturing system, preferably a computer-implemented method, wherein, The electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and a motor controller, wherein the motor is configured to be able to actuate the tissue cutting blade, and the method includes: Controlling, by the motor controller, a pulse width modulated motor control signal to the motor; Receiving, by the motor controller, data regarding an interaction between the tissue cutting blade and the tissue clamped by the anvil; and Adjusting, by the motor controller, the frequency of the pulse width modulated motor control signal based on the data regarding the interaction between the tissue cutting blade and the tissue clamped by the anvil.

45. The method according to claim 44, wherein, Adjusting the frequency of the pulse width modulated motor control signal includes maintaining a first frequency of the pulse width modulated motor control signal when the tissue cutting blade is not in contact with the tissue.

46. The method according to claim 44 or 45, wherein, Adjusting, by the motor controller, the frequency of the pulse width modulated motor control signal includes changing the frequency of the pulse width modulated motor control signal between a first frequency and a second frequency.

47. The method according to claim 46, wherein, Changing the frequency of the pulse width modulated motor control signal between a first frequency and a second frequency includes alternately driving the tissue cutting blade into the tissue at the first frequency and driving the tissue cutting blade away from the tissue at the second frequency.

48. The method according to claim 46, wherein, Changing the frequency of the pulse width modulated motor control signal between the first frequency and the second frequency includes driving the tissue cutting blade at the first frequency when the tissue cutting blade first contacts the tissue and driving the tissue cutting blade at the second frequency after the tissue cutting blade first contacts the tissue, wherein the second frequency is less than the first frequency.

49. A motor controller for a motor in an electrosurgical suturing system, wherein, The electrosurgical suturing system includes an anvil, a tissue cutting blade, an articulating joint, the motor, a motor power source, a motor gear reducer assembly mechanically coupled to the motor, and the motor controller, wherein the motor controller includes a processor configured to execute the method according to any one of claims 29 to 34.

50. An electrosurgical suturing system, the electrosurgical suturing system comprising an anvil, a tissue cutting blade, an articulation joint, a motor, a motor power source, a motor gear reduction assembly mechanically coupled to the motor, and a motor controller, wherein, The motor controller includes a processor configured to execute the method according to any one of claims 44 to 48.

51. A computer program product comprising instructions which, when executed by a processor comprised in a motor controller for a motor in an electrosurgical suturing system, cause the motor controller to perform the method according to any one of claims 44 to 48, wherein, The electric surgical suturing system includes an anvil, a tissue cutting blade, an articulation joint, the motor, a motor power source, a motor gear reduction assembly mechanically coupled to the motor, and a motor controller.

52. A computer-readable data carrier having stored thereon the computer program product according to claim 51.

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