Motor control for surgical instrument systems

Abstract

A surgical instrument system including a motor system and a control circuit is disclosed. The motor system includes a motor and a driveline coupleable to the motor and configured to actuate a firing member through a staple firing stroke. And a control circuit coupled to the motor, where the control circuit includes a motor controller configured to control the motor, and where, during the staple firing stroke, the control circuit is configured to: actuate the firing member through the staple firing stroke; monitoring a parameter of the motor system during the staple firing stroke; identifying when the firing member is within an active adjustment portion of the staple firing stroke; and automatically adjusting a tuning parameter of the motor controller at a frequency based on a monitored parameter of the motor system during the active adjustment portion of the staple firing stroke.

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, can be understood from the following description in conjunction with the accompanying drawings:

[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 a 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 a plurality of 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 Graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, wherein the motor control circuit performs a sensing or interrogation action during the firing stroke to determine whether the speed of the motor can be increased to a target speed;

[0020] Figure 16 Graph depicting a number of firing strokes performed by a motor system including a motor, a drivetrain, and a motor control circuit, wherein performing different sensing actions produces different results;

[0021] Figure 17 Graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, wherein the motor control circuit performs a plurality of discrete sensing actions and, in response to the sensing action, performs a reaction a certain period of time after the sensing action is completed;

[0022] Figure 18 Graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, wherein the motor control circuit performs a sensing action and, in response to the sensing action, performs a reaction a certain period of time after the sensing action is completed;

[0023] Figure 19is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where multiple sensing actions are performed, each sensing action including a different target speed magnitude and a different time period;

[0024] Figure 20 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit performs a sensing action and, in response to the sensing action, performs a reaction after a predetermined time period;

[0025] Figure 21 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit performs multiple sensing actions by increasing a target motor duty cycle, and performs a functional action or reaction after the sensing actions are completed;

[0026] Figure 22 is a logic flowchart depicting a process that can be performed by a control circuit, where the process includes actions for controlling a motor of a surgical instrument system, where the control circuit is configured to be able to perform multiple sequences of sensing actions during a pre-compression phase to determine a firing speed of the motor for a staple firing stroke;

[0027] Figure 23 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where multiple sensing actions are performed by incrementally increasing a target motor duty cycle, and a reaction is performed after the sensing actions are completed;

[0028] Figure 24 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit performs multiple sensing actions by linearly increasing the target speed magnitude of each subsequent sensing action, where the motor control circuit is configured to be able to return the target speed of the motor to the target speed achieved during a previous successful sensing action;

[0029] Figure 25 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit performs multiple sensing actions by increasing the target speed magnitude of each subsequent sensing action by continuously smaller amounts, where the motor control circuit is configured to be able to return the target speed of the motor to the target speed achieved during a previous successful sensing action;

[0030] Figure 26is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit performs a plurality of sensing operations by logarithmically increasing the target speed magnitude of each subsequent sensing operation, and where the motor control circuit is configured to be able to revert the target speed of the motor to the target speed achieved during a previous successful sensing operation;

[0031] Figure 27 is a graph depicting a number of firing strokes performed by a motor system including a motor, a drivetrain, and a motor control circuit, where different sequences of sensing operations are performed by modulating the motor duty cycle of the motor;

[0032] Figure 28 is a graph depicting a primary sensing metric and a secondary sensing metric of a motor control circuit configured to be able to control the speed of a motor;

[0033] Figure 29 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit employs a speed control algorithm during the firing stroke, and where the speed control algorithm utilizes a lockout period when a lockout condition is met;

[0034] Figure 30 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit performs sensing operations and functional operations;

[0035] Figure 31 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit performs sensing operations and, in response to the actual speed of the motor monitored during the decaying sensing operation, performs a plurality of functional operations to reduce the motor speed;

[0036] Figure 32 is a logic flowchart depicting a process executable by a control circuit, where the process includes an action of querying a motor system to determine whether there is excess capacity within the motor system during a drive stroke of the drivetrain;

[0037] Figure 33 is a graph depicting a firing stroke performed by a motor control circuit of a motor system, where the motor control circuit employs a lockout period after a failed sensing operation to prevent subsequent actions from occurring during the lockout period;

[0038] Figure 34 is a logic flowchart depicting a process executable by a control circuit for use in a surgical instrument system, where the control circuit is configured to be able to adjust the parameters of subsequent sensing operations, where the adjustment is based on the monitored results of a first sensing operation;

[0039] Figure 35 is a logic flowchart depicting a process executable by a control circuit for use in a surgical instrument system, where the control circuit is configured to be able to adjust parameters of one or more sensing actions performed during a second firing stroke, and where the adjustment is based on the monitored results of a first sensing action performed during a first firing stroke;

[0040] Figure 36 is a logic flowchart depicting a process executable by a control circuit for use in a surgical instrument system, where the control circuit is configured to be able to adjust parameters of one or more subsequent sensing actions, where the adjustment is based on the monitored success status of the one or more sensing actions;

[0041] Figure 37 is a graph depicting a firing stroke performed by a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit is configured to be able to set a maximum torque output limit during different time periods of the firing stroke;

[0042] Figure 38 is a schematic diagram of different motor duty cycles of a motor of a surgical instrument;

[0043] Figure 39 depicts a control process of a motor control circuit of a surgical instrument, where the motor control circuit is configured to be able to use both the monitored motor duty cycle and the monitored motor speed and / or the firing member speed as inputs for adjusting the motor speed during a drive stroke;

[0044] Figure 40 is a graph depicting various types of signal variables affected by PID controller parameter adjustment;

[0045] Figure 41 is a logic flowchart depicting a process executable by a control circuit configured to be able to adjust motor control parameters based on monitored parameters of a motor system;

[0046] Figure 42 is a graph depicting a firing stroke of a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit divides the firing stroke into multiple parts and adjusts one or more motor control parameters of the motor according to each part;

[0047] Figure 43 is a graph depicting a firing stroke of a motor system including a motor, a drivetrain, and a motor control circuit, where the motor control circuit divides the firing stroke into multiple parts and adjusts one or more motor control parameters of the motor according to the expected load and / or the monitored position of the firing member within the firing stroke;

[0048] Figure 44is a logic flow diagram depicting a process that can be performed by a control circuit of a motor configured to be capable of controlling a motor system;

[0049] Figure 45 is a logic flow diagram depicting a process that can be performed by a control circuit of a motor system configured to be capable of controlling a surgical instrument system;

[0050] Figure 46 is a control diagram of a Δ-Σ modulator;

[0051] Figure 47 is a graph of an analog signal and a resulting pulse amplitude modulation signal;

[0052] Figure 48 is a comparison of motor currents at two different pulse width modulation frequencies, where each signal includes the same duty cycle;

[0053] Figure 49 is a graph showing motor currents at different duty cycles and pulse width modulation frequencies; and

[0054] Figure 50 is a logic flow diagram depicting a process that can be performed by a control circuit of a motor system configured to be capable of controlling a surgical instrument system, wherein the control circuit is configured to be capable of initiating an oscillating drive signal for a motor of the motor system when a current through the motor is detected to exceed a predetermined threshold.

[0055] 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

[0056] 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.

[0057] 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.

[0058] 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 connection with the figures. However, the surgical instrument is used in many orientations and positions, and these terms are not restrictive and / or absolute.

[0059] 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 a natural body cavity, through an incision or puncture 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.

[0060] A surgical stapling system can 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 a 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.

[0061] 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.

[0062] The staples are supported by a staple driver in the cartridge body. The driver is movable between a first or non-firing position and a second or firing position to eject the staples from the staple cavity. The driver is retained in the cartridge body by a retainer that extends around the bottom of the cartridge body and includes an elastic member configured to grip the cartridge body and hold the retainer to the cartridge body. The driver is movable between its non-firing position and its 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 under the driver and lift the driver toward the anvil, and the staples are supported on the driver.

[0063] 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. The longitudinal slot defined in the cartridge housing 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 further includes a first cam engaging the first jaw and a second cam engaging 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 further includes a blade configured to be able to cut into the tissue captured between the staple cartridge and the anvil. It is desirable that the blade be positioned at least partially close to the ramp surface such that the staple is ejected prior to the blade.

[0064] Figure 1 A surgical instrument 1010 is shown that includes an interchangeable shaft assembly 1200 operatively coupled to a housing 1012. Figure 2 An interchangeable shaft assembly 1200 detached from the housing 1012 or the handle 1014 is shown. As Figure 3 can be seen, the handle 1014 may 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. Thus, 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.

[0065] 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 in combination 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 for 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 combination 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.

[0066] 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 can operably support a "first" or closing 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 closing drive system 1030 may include an actuator in the form of a closing trigger 1032 pivotally supported by the frame 1020. More specifically, as Figure 3 shown, the closing trigger 1032 is pivotally coupled to the handle 1014 via a pin 1033. Such an arrangement enables the closing trigger 1032 to be manipulated by a clinician such that when the clinician grasps the pistol grip portion 1019 of the handle 1014, the closing 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 closing trigger 1032 can be biased to the unactuated position by a spring or other biasing arrangement (not shown). In various forms, the closing drive system 1030 also includes a closing link assembly 1034 pivotally coupled to the closing trigger 1032. As Figure 3 can be seen, the closing link assembly 1034 may include a first closing link 1036 and a second closing link 1038 pivotally coupled to the closing trigger 1032 via a pin 1035. The second closing link 1038 may also be referred to herein as an "attachment member" and includes a lateral attachment pin 1037.

[0067] Still referring to Figure 3 it can be observed that the first closure connector 1036 may have a locking wall or locking end 1039 thereon that is configured to cooperate with a closure release assembly 1060 pivotally coupled to the frame 1020. In at least one form, the closure release assembly 1060 may include a release button assembly 1062 having a locking pawl 1064 projecting distally formed thereon. The release button assembly 1062 may be pivotable in a counterclockwise direction by a release spring (not shown). When the clinician presses the closure trigger 1032 from its unactuated position toward the pistol grip portion 1019 of the handle 1014, the first closure connector 1036 pivots upward to a point where the locking pawl 1064 drops into engagement with the locking wall 1039 on the first closure connector 1036, thereby preventing the closure trigger 1032 from returning to its unactuated position. Thus, the closure release assembly 1060 is used to lock the closure trigger 1032 in the fully actuated position. When the clinician desires to unlock the closure trigger 1032 to allow it to be biased to its unactuated position, the clinician simply pivots the closure release button assembly 1062 such that the locking pawl 1064 moves out of engagement with the locking wall 1039 on the first closure connector 1036. When the locking pawl 1064 has moved out of engagement with the first closure connector 1036, the closure trigger 1032 may pivot back to its unactuated position. Other closure trigger locking arrangements and release arrangements may also be employed.

[0068] An arm 1061 may extend from the closure release button assembly 1062. A magnetic element 1063 (such as a permanent magnet) may be mounted to the arm 1061, for example. When the closure release button assembly 1062 rotates from its first position to its second position, the magnetic element 1063 may move toward the circuit board 1100. The circuit board 1100 may include at least one sensor configured to detect movement of the magnetic element 1063. In at least one embodiment, for example, a "Hall effect" sensor (not shown) may be mounted to the bottom surface of the circuit board 1100. The Hall effect sensor may be configured to detect a change in the magnetic field surrounding the Hall effect sensor caused by movement of the magnetic element 1063. The Hall effect sensor may communicate signals with, for example, a microcontroller that may determine whether the closure release button assembly 1062 is in its first position associated with the unactuated position of the closure trigger 1032 and the open configuration of the end effector, its second position associated with the actuated position of the closure trigger 1032 and the closed configuration of the end effector, and / or any position between the first position and the second position.

[0069] In at least one form, the handle 1014 and the frame 1020 are operably supported by another drive system herein referred to as the 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 can be seen, 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 operable attachment 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.

[0070] 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 reducer 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 be able 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 be able to detect the position of the drive member 1120 and / or the direction in which the drive member 1120 is moving.

[0071] 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 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, a 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 such that it is not 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.

[0072] 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 the 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 ratchet 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 an emergency arrangement 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.

[0073] 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 found 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 entire 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 can be seen, the interchangeable shaft assembly 1200 may further include a proximal housing or nozzle 1201 consisting of nozzle portions 1202 and 1203.

[0074] 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 within 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 an articulation axis AA about which the surgical end effector 1300 can articulate relative to the shaft axis SA. See Figure 2 .

[0075] In the illustrated example, the surgical end effector 1300 can be selectively articulated about the articulation axis AA by an articulation system 2100. In one form, the articulation system 2100 includes a proximal articulation driver 2102 that is pivotally coupled to an articulation link 2120. As Figure 5It can be seen most specifically that 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 attachment 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 AXIALLYMOVABLE CLOSURE MEMBER", now U.S. Patent Application Publication 2019 / 0000464, the entire disclosure of which is hereby 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.

[0076] 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.

[0077] 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 that are 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 an 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 an unactuated position when the shaft assembly is operatively coupled to the handle 1014.

[0078] 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 upwardly projecting upper shank 3052 and a lower shank 3054. The upper double-pivot connector 3056 includes upwardly projecting distal and proximal pivot pins that engage an upper distal pin hole in the upwardly projecting upper shank 3052 on the distal closing tube segment 3030 and an upper proximal pin hole in the upwardly projecting upper shank 3032, respectively. The lower double-pivot connector 3058 includes upwardly projecting distal and proximal pivot pins that engage a lower distal pin hole in the upwardly projecting lower shank 3054 and a lower proximal pin hole in the upwardly 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 an open position.

[0079] 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 to attach to the 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 the staple cartridge 1301 positioned within the channel 1310. The knife bar 1910 includes a knife portion 1920 and includes an upper anvil engagement tab 1924 and a lower channel engagement 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.

[0080] 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.

[0081] 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 articulation drive. A 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, the openings being 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 to be received in 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 operatively engage and disengage the articulation 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 articulation 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 articulation system is disconnected from the firing drive system.

[0082] 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 TISSUETHICKNESS 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.

[0083] 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 can be rotatable 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 operably 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 operably 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 be able to detect the position of the switching cylinder 1500.

[0084] 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 .

[0085] Various shaft assembly embodiments employ a latching 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 the illustrated embodiment, for example, the locking yoke 1712 is U-shaped and has two spaced-apart legs 1714 that extend downwardly. 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 locking lugs 1716 that project proximally and 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 that 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 corresponding locking ratchets or grooves 1704 in the distal attachment flange portion 1700.

[0086] 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 the desired orientation, the clinician may 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.

[0087] As Figure 4As can be seen most specifically, the locking yoke 1712 includes at least one, and preferably two, locking hooks 1718 that are adapted to engage 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 engage 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 engage the locking lug portions 1256 on the closure shuttle 1250 and prevent the locking yoke 1712 from moving to the unlocked position.

[0088] 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 so doing, 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 thereto, the components can perform their intended actions, functions, and / or procedures.

[0089] At least five systems of the interchangeable shaft assembly 1200 can be operatively coupled to 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 operatively connects the closure trigger 1032 of the handle 1014 to 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 operatively connects the firing trigger 1130 of the handle 1014 to the intermediate firing shaft portion 1222 of the shaft assembly 1200. As outlined above, the shaft attachment lug 1226 can be operatively connected to the 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 shaft assembly 1200) has been operatively 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 operatively mounted to a shaft circuit board 1610. The electrical connector 1810 is configured to mate 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 in their entirety. The fifth system can consist of a latch system for releasably locking the shaft assembly 1200 to the handle 1014.

[0090] In the illustrated example, the anvil 2000 includes an anvil body 2002 that terminates in an anvil mounting portion 2010. The anvil mounting portion 2010 is movably or pivotally supported on the elongate channel 1310 for selective pivotal travel relative to the elongate channel about a fixed anvil pivot axis PA that is transverse to the shaft axis SA. In the illustrated arrangement, pivot members or anvil trunnions 2012 extend laterally out from each lateral side of the anvil mounting portion 2010 to be received within corresponding trunnion brackets 1316 formed in upright walls 1315 of a proximal end portion 1312 of the elongate channel 1310. The anvil trunnions 2012 are pivotally retained within their corresponding trunnion brackets 1316 by a channel cover or anvil retainer 1290. The 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 the upright walls 1315 of the proximal end portion 1312 of the elongate channel 1310. See Figure 5 。

[0091] Still referring to Figure 5 , in at least one arrangement, the distal closure member or end effector closure tube 3050 employs two axially offset proximal positive jaw opening features 3060 and distal positive jaw opening features 3062. The positive jaw opening features 3060, 3062 are configured to interact with corresponding release areas and stepped portions formed on the anvil mounting portion 2010, as further described in 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.

[0092] Figure 6 and Figure 7 Illustrated is a shaft assembly 100. The shaft assembly 100 includes an attachment portion 110, a shaft 120 that extends distally from the attachment portion 110, and an end effector 130 that is attached to the shaft 120. The shaft assembly 100 is configured to grasp, suture, and cut tissue. The 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.

[0093] See Figure 7 , the shaft assembly 100 includes cooperating articulation levers 144, 145 that are configured to articulate the end effector 130 relative to the shaft 120 about an articulation joint 160. The shaft assembly 100 further includes an articulation lock lever 148, an outer shaft tube 162, and a ridge portion 123.

[0094] See Figure 7 , the shaft 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 cause the firing member 156 to be advanced 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", which is hereby incorporated by reference in its entirety.

[0095] 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 can be adapted to handle tissue in any suitable manner, such as, for example, by applying thermal energy, electrical energy, and / or vibration to the tissue. The surgical instrument assembly 200 includes a proximal control interface 210 configured to be coupled to the 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 "SURGICAL INSTRUMENTS WITH DUAL ARTICULATION DRIVERS", which is hereby incorporated by reference in its entirety.

[0096] 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 and can be combined with Figure 11A type of robotic arm depicted in the main controller 301 used by the moving vehicle 310. The main controller 301, the robotic arm moving vehicle 310, and 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 disclosures of which are 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 a 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 actuatable handles for actuating tools (e.g., for closing grasping jaws, applying electrical potential to electrodes, etc.).

[0097] 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 supporting the parallelogram links 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. Accordingly, 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 structures and device arrangement structures are also contemplated. Examples of other joint and device arrangement structures 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 described herein primarily in connection with communication between a surgical tool and the 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 confirmation, component type identification, component calibration (such as offset, etc.) communication, component and robotic surgical system coupling confirmation, 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.

[0098] 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).

[0099] 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 may include any number of components adapted to transfer motion to the end effector 1940, such as, for example, one or more linkages, rods, tubes, and / or cables.

[0100] 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 may 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 may 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.

[0101] In addition to the above, in various arrangements, the sensors 1938 may 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 be able to detect electrical characteristics of a tissue passageway (such as capacitance or resistance), or any combination thereof. As another example, but not limited to, the sensors 1938 may include one or more sensors located at or around a joint movement joint extending proximally from the end effector 1940. Such sensors may 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 may include multiple sensors located at multiple positions within the end effector 1940.

[0102] In certain aspects, the system 1930 may include a feedback system 1952 that includes one or more devices for providing sensory feedback to the user. Such devices may include, for example, visual feedback devices (e.g., LCD displays, touchscreens, LED indicators), audio feedback devices (e.g., speakers, buzzers), or tactile feedback devices (e.g., tactile actuators).

[0103] 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 as ARM Cortex produced by Texas Instruments. In one aspect, the main microcontroller 1933 can be the 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 seen in the product data sheet.

[0104] The microcontroller 1933 can be configured to be able to calculate the response in the software of the microcontroller 1933. The calculated response is compared with the measured response of the actual system to obtain the "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.

[0105] 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 the A3941 purchased from Allegro Microsystems, Inc.

[0106] In various forms, the motor assembly 1939 includes a brushed DC drive motor with a maximum rotational speed of about 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).

[0107] The motor assembly 1939 can be powered by a power source 1942. The power source 1942 can include one or more batteries, and the one or more batteries 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 component 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 component.

[0108] 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 striking force applied to the jaws 1921, 1931.

[0109] 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.

[0110] In one form, a strain gauge sensor can be used to measure, for example, the force applied by the end effector 1940 to tissue. 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.

[0111] The 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.

[0112] 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.

[0113] In various aspects, control circuit 1932 may be configured to be capable of implementing 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 be capable of receiving instructions from the memory circuit of the present disclosure.

[0114] Alternatively, in certain cases, control circuit 1932 may be in the form of a combinatorial logic circuit configured to be capable of implementing the various processes described herein. The combinatorial logic circuit may include a finite state machine that includes combinatorial logic configured to be capable of receiving data, processing the data by the combinatorial logic, and providing an output.

[0115] 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 be capable of implementing the various processes described herein. The sequential logic circuit may include a finite state machine. The sequential logic circuit may include, for example, combinatorial 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 combinatorial logic circuit and a sequential logic circuit.

[0116] Figure 14 FIG. 600 shows a block diagram of a surgical system 600 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 in the same detail herein 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.

[0117] 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, the plurality of motors can be individually activated to cause, for example, a firing motion, a closing motion, and / or an articulation motion in the end effector 1940. The firing motion, closing motion, and / or articulation motion can be transmitted to the end effector 1940, for example, via a shaft assembly.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] As described above, system 600 may include a plurality of motors, which may be configured to perform various independent functions. In some cases, the plurality of motors of the 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 a plurality of staples and / or advance the cutting blade while articulation motors 606 remain inactive. Additionally, closure motor 603 may be activated simultaneously with firing motor 602 to advance the closure tube and I-beam element distally, as described in more detail below.

[0122] In some cases, system 600 may include a common control module 610, which may be used with the plurality of motors of the surgical instrument or tool. In some cases, common control module 610 may adjust one of the plurality of motors at a time. For example, common control module 610 may be individually coupled to and decoupled from the plurality of motors of the surgical instrument. In some cases, the plurality of motors of the surgical instrument or tool may share one or more common control modules such as common control module 610. In some cases, the plurality of motors of the 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 plurality of motors of the surgical instrument or tool to interfacing with another of the plurality of motors of the surgical instrument or tool.

[0123] 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 closure 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.

[0124] 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.

[0125] 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 an input 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 employed, for example, to determine the current consumed by the motor, as described above.

[0126] 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.

[0127] 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 an input from an algorithm or control program of the surgical instrument or tool.

[0128] 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 to 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 the program instructions associated with the I-beam of the firing end effector when, for example, switch 614 is detected by sensor 630 to be in the first position 616; processor 622 can use the program instructions associated with closing the anvil when, for example, switch 614 is detected by sensor 630 to be in the second position 617; and processor 622 can use the program instructions associated with articulating the end effector when, for example, switch 614 is detected by sensor 630 to be in the third position 618a or the fourth position 618b.

[0129] In various cases, one or more mechanical outputs of a motor system that includes a motor and a drivetrain connected to the motor can be used as inputs to a motor control circuit that controls the motor to increase the efficiency of the motor system. In at least one case, the drivetrain includes a closure member that is coupled to a motor configured to be able to grasp tissue with an end effector. In at least one case, the drivetrain includes a firing member that is coupled to a motor configured to be able to move the firing member through a firing stroke. In at least one case, the firing stroke includes a staple firing stroke. In at least one case, the firing stroke includes a portion where the firing member grasps a portion of the tissue with the jaws of the end effector and another portion where the firing member deploys staples from the end effector to suture and cut the tissue grasped by the end effector.

[0130] The mechanical output of the motor can include any suitable mechanical output. For example, the mechanical output can include the actual speed of the motor, the actual displacement of the motor (e.g., measured with an encoder), and / or the amount of elapsed time that the motor has been running. In addition to the foregoing, the mechanical output can include, for example, the heat generated by the motor and / or the force generated by the drivetrain. Such outputs can be measured directly and / or indirectly in any suitable manner.

[0131] In various cases, a motor system that includes a motor and a drivetrain connected to the motor may be underutilized (e.g., the motor speed can be increased without fear of overstraining the motor system), overutilized (e.g., the motor is operating at a speed that is close to or has already overstrained the motor system), and / or fully utilized (e.g., the motor is operating at a speed at which the motor system is neither overstrained nor is there room to increase the motor speed). In other words, the motor system is operating below its maximum or optimal capacity, the motor system is operating at its maximum capacity, and / or the motor system is operating above its maximum capacity.

[0132] For example, depending on the utilization of the motor system, adjustments can be made through the motor control circuit to improve the efficiency of the motor system. Such adjustments can include dynamic adjustments of the motor. In at least one case, the adjustment includes dynamic control of the motor speed. For example, overstraining the motor system can include operating the motor at a duty cycle outside of a threshold duty cycle range, which may cause the motor to fail faster than expected. In various cases, the capacity of the motor system can be measured to determine the utilization of the motor system. The duty cycle of pulse width modulation (PWM) motor control can vary, for example, in terms of percentage width and magnitude.

[0133] In at least one case, the motor control circuit is configured to be able to interrogate and / or determine the relative capacity of the motor system. In at least one case, the interrogation of the relative capacity of the motor system includes monitoring parameters of one or more components of the driveline and / or the motor. For example, the relative capacity of the motor system can be monitored at any suitable time. In at least one case, the relative capacity of the motor system is automatically monitored before the clamping stroke, during the clamping stroke, after the clamping stroke but before the nailing stroke, during the nailing stroke, near the end of the nailing stroke, and / or after the end of the nailing stroke. In at least one case, the interrogation of the relative capacity of the motor system is manually initiated by the user of the instrument. For example, the relative capacity of the motor system can also be referred to as the unused or available capacity of the motor and / or the motor system relative to the maximum capacity.

[0134] Adjustments to the motor system can be made by the motor control circuit at any suitable time. For example, when the motor system is interrogated and the relative capacity of the motor system is determined, the adjustment of the motor system can be made simultaneously and / or at least substantially simultaneously. The interrogation of the motor system can be referred to as an interrogation action, a sensing action, and / or a microstep. These actions can also be referred to as steps, such as, for example, an interrogation step and / or a sensing step. In at least one case, for example, the adjustment of the motor system can be made after a predetermined set time interval measured from the time of the interrogation action and / or after the interrogation action is completed.

[0135] In at least one instance, the relative capacity of the motor system is repeatedly monitored and / or measured at a desired frequency over a period of time. In addition to the above, the motor system can be adjusted based on the measured relative capacity. Such adjustments can be made at the same and / or different frequencies than the frequency at which the relative capacity of the motor system is measured. For example, each frequency can be adjusted automatically and / or manually to better accommodate different scenarios. For example, the frequency of measuring the relative capacity of the motor system for the jaws of the grasping end effector may be higher than the frequency of the motor system that deploys the firing member, and vice versa. In at least one instance, the frequency of monitoring the relative capacity of the motor system that deploys the firing member is higher than the corresponding frequency at which the same motor system is adjusted. For example, such an arrangement can increase the stability of the motor system during a nailing stroke.

[0136] Various types of adjustments can be made when determining the relative capacity of the motor system. For example, the motor system can be paused, a lock can be activated, the motor can be slowed down, the motor can be sped up, the speed of the motor can remain the same, and / or another interrogation action can be performed to verify a previously determined relative capacity.

[0137] In at least one instance, for example, the speed of the motor is incrementally increased at a certain frequency in an effort to maximize the operating efficiency of the motor system. With each incremental speed increase, the relative capacity of the motor system is determined by measuring the actual mechanical output of the motor system (such as, for example, the actual speed of the motor). The actual speed of the motor can be used to determine whether the motor system is operating in a predicted or expected state in response to each incremental speed increase of the motor. For example, if the actual speed of the motor is as expected after an incremental speed increase of the motor, it can be determined that the motor system is operating at or below its maximum or optimal capacity. In such a case, the speed of the motor is incrementally increased again, and the relative capacity of the motor system is determined again. After one or more incremental speed increases, the actual speed of the motor may not be as expected, and it can be determined that the motor system is operating above its maximum capacity. In such a case, a variety of things can occur, which will be discussed in more detail below.

[0138] If it is determined that the motor system is operating at or above its maximum or optimal capacity after an incremental speed increase, the user may receive a warning, the motor system may be adjusted in any suitable manner, and / or the motor system may not be adjusted. In at least one case, the speed of the motor is reduced back to its previous speed. For example, if the motor experiences five incremental speed increases from an initial speed and it is determined at the fifth incremental speed increase that the motor system is operating above its maximum capacity, the speed of the motor may be reverted to the speed set for the fourth incremental speed increase. In at least one case, the reverted speed is equal to the speed set for the fourth incremental speed increase. In at least one case, the reverted speed is a percentage of the speed set for the fourth incremental speed increase so as not to operate the motor system close to its maximum capacity, but rather to operate the motor system at a certain percentage below the maximum capacity. Such an arrangement can extend the life of the motor system, for example, by rarely operating the motor system at its maximum capacity. In at least one case, the maximum capacity is pre-determined to be lower than the actual maximum capacity, such as, for example, the absolute mechanical capacity of the motor system. The actual maximum capacity of the motor system may be, for example, as recommended by the manufacturer.

[0139] In various cases, the incremental speed increases are not obvious or perceivable to the user. For example, such non-perceivability may be measured by, for example, the vibration yield of a surgical instrument system being below a predefined perceivable threshold. In at least one case, the time period during which the speed increase is performed is below a perceivable time threshold so as to reduce the likelihood of the user noticing the speed increase. In at least one case, the frequency of the speed increases is high, but the magnitude of each incremental speed increase is low compared to the actual speed of the motor. Thus, the motor system is able to constantly adjust the speed of the motor, for example, to increase efficiency and / or maintain maximum efficiency, without affecting the user's experience. Such an arrangement can prevent jerking of systems that significantly increase the motor speed, for example, during a stapling stroke.

[0140] In at least one case, after determining that the motor system is operating at its maximum or optimal capacity, a delay is employed so as not to immediately restart the interrogation of the motor system. In at least one case, no delay is employed and the motor system is constantly interrogated regardless of the adjustments made to the motor.

[0141] Interrogating the relative capacity of the motor system may also be referred to as sensing the relative capacity of the motor system. For example, one or more sensing actions may be performed to determine when the speed of the motor can be increased.

[0142] Figure 15FIG. 13000 is a graph depicting an example of a sensing action 13004 performed to determine whether the speed of a motor can be increased. As can be seen in FIG. 13000, the target speed 13001 increases to a first target or set speed at the start of stroke 13003 (position 0). In response, the measured speed 13002 increases until the motor reaches a first measured speed. In at least one case, the first measured speed is as expected and thus the sensing action can be performed. The first target speed and the first measured speed may be the same or may be different. At sensing action 13004, the speed of the motor is increased by a predetermined amount to a second target speed. In response, the measured speed 13002 gradually increases to a second measured speed. The measured speed or actual speed 13002 can vary due to a variety of factors, such as, for example, motor performance, tissue type encountered, and / or drivetrain recoil. At this point, based on the system response to sensing action 13004 (e.g., the actual measured speed of the motor relative to the second target speed), the second target speed is maintained so that the motor operates at the second target speed. The actual existence of additional or excess capacity can be determined based on the magnitude of the difference or deviation between the actual measured speed of the motor and the second target speed. In at least one case, if excess capacity is not available, the target speed may revert to the first target speed.

[0143] In various cases, the sensing action results in a permanent action of setting a final or optimal speed by the control circuit. In other words, the increase in the motor speed performed during the interrogation action of the motor system is maintained for the remainder of the stroke, or if the target speed or a predetermined percentage of the target speed is not reached during the performance of the sensing action, it is determined that additional capacity is not available and the speed of the motor reverts to the speed at which the motor was operating prior to the speed increase.

[0144] Figure 16 FIG. 13010 is a graph depicting different staple firing strokes 13011, 13012, and 13013 and the results of interrogating a motor system performing different staple firing strokes 13011, 13012, and 13013 in an effort to determine the relative capacity of the motor system. Also shown are the closing load (the load experienced by the clamping jaws) and the stroke position (the position of the firing member throughout the closing and firing strokes). For example, for each staple firing stroke 13011, 13012, and 13013, the force required to fire the firing member is also shown. The initial firing force for stroke 13011 is F0, the initial firing force for stroke 13012 is F1, and the initial firing force for stroke 13013 is F2. As is also Figure 16 visible, various events corresponding to, for example, a surgical stapling instrument are also shown on FIG. 13010: the clamping period (with a partial clamp indicator Tpc and a full clamp indicator Tfc), the pre-fire or pause period, and the firing period.

[0145] In addition to the above, the actual speed or rate of the I-beam or firing member for each nail drive stroke 13011, 13012, and 13013, respectively, and the target speed 13020 utilized in the sensed motion of each drive stroke are also shown. As can be seen in graph 13010, the target speed 13020 increases from zero to V0 at the start of the drive stroke, for example, by a motor control circuit. For example, the speed V0 can be used to apply full clamping pressure to the jaws of the end effector having the I-beam. After time t1, the motor control circuit performs a sensed motion and attempts to increase the motor speed to V1 for each nail drive stroke 13011, 13012, and 13013.

[0146] In response to the increase in the speed of the motor during nail drive stroke 13011, the driving force is relatively low, and thus the actual speed 13021 of the motor remains at an acceptable percentage of or within the range of the target speed V1. The actual speed 13021 is measured, and once it is determined that the actual speed 13021 of the motor reaches an acceptable percentage of or within the range of the target speed V1, the motor control circuit maintains the target speed V1 for the remainder of nail drive stroke 13011. In response to the increase in the speed of the motor during nail drive stroke 13012, where an increased driving force is experienced in addition to the intermediate stroke increase in the driving force, the actual speed of the motor remains within an acceptable level relative to the target speed V1. For clarity, the actual speed of nail drive stroke 13012 is shown as the same as the actual speed 13021. In this case, the motor control circuit maintains the target speed V1 for the remainder of nail drive stroke 13012. In response to the increase in the speed of the motor during nail drive stroke 13013, where the driving force is relatively high at the start and experiences a large intermediate stroke increase in the driving force, the actual speed 13023 of the motor does not reach the target speed V1, nor can the actual speed 13023 of the motor reach a speed within an acceptable percentage of the target speed V1. In this case, the motor control circuit returns the target speed of the motor to the target speed V0 after time period t2. In at least one case, the motor control circuit returns the target speed of the motor to a predetermined percentage of the target speed V0 and / or a predetermined amount of speed above and / or below the target speed V0. In at least one case, the amount of adjustment is based on the magnitude of the deviation between the actual measured speed and the target speed.

[0147] The sensed motion performed during nail drive strokes 13011, 13012, and 13013 includes time period t2. In other words, the target speed V1 can be maintained at V1 during time period t2. Time period t2 can be any suitable time period.

[0148] In various cases, for example, a sense action occurs before or precedes a reaction or a permanent action. In other words, the speed of the motor increases, the relative capacity of the motor system is determined, the speed of the motor returns to its initial speed, and later during the nailing stroke, the speed of the motor increases in response to the determined relative capacity of the motor system obtained during the sense action. In at least one case, multiple sense actions are performed before the reaction.

[0149] Figure 17 is a graph 13040 depicting the actual speed 13042 of the nailing stroke relative to the target speed 13041 of the nailing stroke. The relative capacity of the motor system is interrogated during an interrogation action 13043. The interrogation action 13043 occurs before a reaction or optimization action 13044. Each interrogation action 13043 includes an increase in the motor speed. In at least one case, the interrogation actions 13043 include different target speeds. In at least one case, the target speed of a subsequent interrogation action 13043 is set based on the response or determined relative capacity of the motor system during a previous interrogation action 13043. During the nailing stroke, the target speed increases after one or more interrogation actions during the reaction or optimization action 13044 are completed. In at least one case, a period of time elapses after the last interrogation action 13043 and before the target speed of the motor increases during the reaction action 13044.

[0150] In at least one case, the user receives a warning before a reaction or optimization action is performed. For example, after the motor control circuit performs one or more non - obvious interrogation actions, the user can be notified via the user interface that the motor system is operating below maximum capacity. For example, the user can then select whether to perform the recommended reaction and / or modify the recommended reaction.

[0151] In various cases, the magnitude of the increase in the speed of the motor during multiple sense or interrogation actions gradually increases in magnitude for each subsequent interrogation action. Figure 18is a graph 13050 depicting the target speed 13051 and the actual speed 13052 of a nailing firing stroke including an interrogation action 13053 and a reaction 13054. During the nailing firing stroke, the speed of the motor increases from a first current speed to a first target speed during the interrogation action 13053. After the interrogation action 13043 is completed, the reaction 13054 occurs, in which the speed of the motor increases to a second target speed greater than the first target speed when it is determined that the relative capacity of the motor system is not close to, equal to, or higher than the maximum capacity during the interrogation action 13053. In at least one case, the ratio of the first target speed to the second target speed is predefined. For example, the target speed of the interrogation action may include, for example, between about 10% and 90% of the target speed of the reaction. In at least one case, for example, the target speed of the interrogation action may include half, a quarter, and / or a third of the target speed of the reaction. Any suitable ratio may be utilized. In at least one case, the target speed of the interrogation action is greater than the target speed of the reaction.

[0152] Figure 19 is a graph 13060 depicting the nailing firing stroke 13061 of a motor system undergoing multiple interrogation actions. Also shown is the closing load (the load experienced by the clamping jaws) and the stroke position (the position of the firing member throughout the closing and firing strokes). For example, for the nailing firing stroke 13061, the force required to fire the firing member is also shown. In addition to the above, the actual or response speed or rate 13065 and the target speed 13063 of, for example, an I-beam or the firing member for the nailing firing stroke 13061 are also shown. As can be seen in the graph 13060, multiple sensing actions are performed targeting speeds V1, V2, and V3. The target speed V1 is interrogated within time t2, the target speed V2 is interrogated within time t4, and the target speed V3 is interrogated within time t6. The time periods t2, t4, and t6 are different. In at least one case, the time period for each sensing action is the same. As can be seen in the graph 13060, the time periods t2, t4, and t6 gradually become longer for each subsequent sensing action. As can also be seen in the graph 13060, for each subsequent sensing action, the amount by which the target speed increases each time gradually increases. During the nailing firing stroke 13061, the actual speed 13065 of the motor is within an acceptable level relative to the target speed 13063 of each sensing action. As in Figure 19As can be seen, the loads experienced by the firing member do not cause the target speeds V1, V2, and V3 to be missed. In other words, the control circuit determines that the motor system can operate at the target speeds V1, V2, and V3 under load. However, in at least one case, if the load increases, the actual speed may change, and thus the motor system may not be able to reach the target speeds V1, V2, and / or V3. In at least one case, as a result of reaching the target speeds V1 and V2, the target speed V3 is the final optimal speed set by the control circuit.

[0153] In at least one case, the period of time for maintaining the target speed for each sensory action is doubled for each subsequent sensory action. In at least one case, the magnitude of the target speed for each sensory action is the same until the target speed can be reached. In this case, the speed of the motor is permanently set at the target speed, and a new target speed is set for subsequent sensory actions until the new target speed can be reached.

[0154] In at least one case, the set of target speeds selected for a sensory action during a staple firing stroke may be referred to as a target speed profile. In at least one case, the target speed profile may be preselected for different types of instruments and / or predefined by the user. For example, a surgical stapling instrument having a 60 mm staple cartridge may include a first target speed profile, while a surgical stapling instrument having a 45 mm staple cartridge may include a second target speed profile different from the first target speed profile. In at least one case, one surgical stapling instrument may require a sensory action with a target speed having a greater magnitude than another surgical stapling instrument to increase the operating efficiency of each corresponding motor. In other words, for example, a motor of one system designed to operate at a higher speed may require a sensory action with a target speed having a greater magnitude than a second system designed to operate at a lower speed to have a more effective response during the staple firing stroke. In at least one case, for example, the period of time for each sensory action includes a length that is not perceivable by the user during use of the surgical stapling instrument. In at least one case, for example, the magnitude of the target speed for each sensory action includes a magnitude that is not perceivable by the user during use of the surgical stapling instrument.

[0155] Figure 20A graph 13070 depicting the target speed 13071 and the actual speed 13072 of a nailing stroke including an interrogation action 13073 and a reaction 13074. During the nailing stroke, the speed of the motor increases to a first interrogation target speed during the interrogation action 13073. After the interrogation action 13073 is completed, a reaction 13074 occurs, wherein when it is determined by comparing the interrogation response speed with the first interrogation target speed that the relative capacity of the motor system is not close to, equal to, or higher than the maximum capacity during the interrogation action, the speed of the motor increases to a second reaction target speed greater than the first interrogation target speed. In at least one case, a time period 13075 is set to warn the user that, for example, a reaction is about to occur. Since the first interrogation target speed is reached or at least an acceptable percentage of the first interrogation target speed is obtained during the interrogation action 13073, the motor control circuit warns the user that the conditions for a set reaction or a permanent action have been met within the time period 13075. In at least one case, the time period 13075 includes warning the user audibly at the start of the time period 13075, and at the end of the time period 13075, the reaction 13074 is initiated (the motor is set to the second reaction target speed).

[0156] In various cases, the sensing action involves the motor control circuit setting a sensed or interrogation target speed for the motor to reach. However, any suitable variable of the motor system can be set. For example, in at least one case, the displacement of the firing member is set and measured. For example, a target displacement can be set and the actual displacement measured and compared with the target displacement to determine whether the motor system is below, close to, at, and / or above the maximum capacity. In at least one case, the motor current, motor voltage, motor duty cycle, and / or motor displacement are used to set the target variable and the measured variable or response variable is compared with the target variable.

[0157] Figure 21 A graph 13080 depicting the target speed 13081 and the actual speed 13082 of a nailing stroke including a plurality of incremental interrogation actions 13083 and one reaction or functional action 13084. The graph 13080 also shows the set duty cycle 13085 of the pulse width modulation circuit of the motor during the nailing stroke. As can be seen in the graph 13080, the set duty cycle increases incrementally 13086 during the sensing or interrogation action 13083, and the set duty cycle increases significantly 13087 during the reaction 13084. The duty cycle can increase at any suitable rate and to any suitable magnitude. In at least one case, the rate of change of the duty cycle and / or the magnitude of the duty cycle change are based on the length of the interrogation action, the length of the nailing stroke, and / or the desired speed of the nailing stroke. In at least one case, the increment between each set duty cycle is small enough that it is not perceptible to the user during the nailing stroke. As in Figure 21As can be seen, during each interrogation operation, the duty cycle increment increases by 5%, and increases to 95% during the reaction. In at least one case, for example, the increment increase includes increasing the duty cycle between about 1% and about 10%. In at least one case, the increase in the duty cycle during the reaction includes increasing the duty cycle by a predefined percentage (e.g., between about 25% and about 50%). In at least one case, the increase in the duty cycle during the reaction includes increasing the duty cycle to a maximum percentage, such as for example about 85%, about 90%, about 95% and / or about 99%.

[0158] In at least one case, the type, thickness and / or toughness of the tissue, the force for firing the firing member during the stapling stroke and / or system losses (e.g., recoil) may be decisive factors for determining whether the motor system can handle a significant speed increase during subsequent interrogation operations and / or reactions. For example, thicker tissue can result in a higher firing force, which can place the motor system at, near and / or above its maximum capacity. Thinner tissue can result in a lower firing force, which can place the motor system well below its maximum capacity. In such a case, the magnitude of the set variables for the reaction can be significantly increased to reflect the increased relative capacity of the motor system.

[0159] As discussed herein, the relative capacity of the motor system can be determined in any suitable manner. In at least one case, the relative capacity of the motor system can be determined by monitoring the relationship between the set target variable and the corresponding actual measured variable during the interrogation operation and / or reaction.

[0160] For example, in the case of motor speed, a first target speed is set and the corresponding actual speed is measured. This speed can be measured at the motor output (the speed of the output shaft) and / or within the end effector (e.g., the speed of the firing member, knife and / or slider). In at least one case, the actual speed of the motor output shaft and the actual speed of the firing member within the end effector are compared and averaged. In any case, for example, the actual speed of the motor output shaft is compared with the set first target speed. In at least one case, the difference between the target speed and the actual measured speed can reflect the relative capacity of the motor system. For example, it can be determined that a 10% speed difference indicates that the motor system is not at full capacity (and / or for example anywhere between about 5% and about 95%). For example, a 10% difference may be the result of system losses such as heat and / or recoil. If the difference between the target speed and the actual measured speed is 15% (greater than 10%), this can indicate that a smaller relative capacity of the motor system is available. If the difference between the target speed and the actual measured speed is close to or about 100%, this can indicate that the motor system is close to, at or exceeding its maximum capacity.

[0161] In at least one case, the threshold magnitude is set by the user, automatically set by a control circuit, or predetermined for one or more sensing operations and / or one or more reactions. In various cases, the threshold magnitude for a sensing operation and / or reaction is adjusted based on the type of instrument, the length of the staple cartridge, the size of the staples in the staple cartridge, the type of tissue being cut and sutured, and / or the articulation position of the end effector. For example, in some cases, the firing shaft is flexible and passes through the articulation joint into the end effector. In such a case, when the end effector is in an articulation position (such as, for example, a full articulation position), the firing shaft may be subject to increased loading. Accordingly, the threshold magnitude of the target variable for the sensing operation and / or reaction may be decreased to more quickly prevent overstraining of the motor system.

[0162] In at least one case, the control circuit monitors the articulation position based on input from one or more sensors. The control circuit may select the threshold magnitude of the target variable for the sensing operation and / or reaction based on input from one or more sensors indicating the articulation position.

[0163] When the end effector is in an articulation position, it may be desirable to decrease the threshold magnitude of a target parameter (such as, for example, a target speed) for one or more sensing operations in order to achieve optimal efficiency at a rate similar to the rate at which optimal efficiency is achieved when the end effector is in its straight configuration. In other words, greater torque may be required to drive a flexible firing member, such as through the articulation joint when the end effector is articulated and thus through the staple firing stroke. In such a case, the control circuit may determine that, despite any other variables, more motor capacity will be used to deploy the firing member through the staple firing stroke when the end effector is in an articulation position. In such a case, for example, when the end effector is articulated relative to a target speed at which the control circuit would set for an end effector in a straight configuration to attempt to reduce one or more failed sensing operations, the control circuit may automatically reduce the target speed.

[0164] In at least one case, for example, the duration of a sensing operation may be adjusted based on the type of instrument, the length of the staple cartridge, the size of the staples in the staple cartridge, the type of tissue being cut and sutured, and / or the articulation position of the end effector. In at least one case, a maximum time threshold is set for the duration of the sensing operation. In at least one case, a minimum time threshold is set for the initiation of a reaction or a functional operation. For example, a request to increase the motor speed may be made by the user or automatically by the motor control circuit, at which time a timer is set to prevent a reaction from occurring before the timer expires. In at least one case, the reaction delay, including a further increase in speed, continues until the timer expires. In at least one case, the reaction delay, including a decrease in speed, continues until the timer expires.

[0165] In at least one instance, a sensing action is performed on the motor system by a motor control circuit during pre-compression. In at least one instance, pre-compression refers to the time after the tissue has been initially clamped but before the start of the firing stroke, during which additional clamping load may be applied to the tissue. In at least one instance, the I-beam within the end effector is configured to travel a predefined amount of distance before the start of the firing stroke (such as, for example, before contacting the unfired slider and / or lock) and after the tissue has been initially clamped. As discussed herein, the firing function and the clamping function can be actuated independently by separate and distinct drive systems. Also as discussed herein, the firing function and the clamping function can be actuated by a single firing drive member. Pre-compression can be present in each of these arrangements. In at least one instance, pre-compression is defined as the time or distance between partial clamping of the tissue and full clamping of the tissue.

[0166] Within a predefined amount of distance, one or more sensing actions can be performed to determine the speed at which the firing member is deployed through the firing stroke. In at least one instance, the firing member is driven forward, backward, and forward again one or more times within the predefined amount of distance, such as to continuously monitor the relative capacity of the motor system before the start of the firing stroke. In at least one instance, the number of times the firing member is driven forward and backward to perform one or more sensing actions depends on the tissue clamped within the end effector. For example, the tissue clamped within the end effector may require time to settle and / or stabilize. In at least one instance, the firing member repeatedly cycles through forward and backward cycles until the tissue is stable. This initial movement of the firing member before contacting the slider can provide an arrangement capable of assessing the initial firing load expected during the firing stroke. As discussed herein, in addition to the sensing actions and / or responses that occur within the initial movement of the firing member, the length, time, and / or speed of this initial movement can be selected, set, and / or defined such that it is imperceptible to the user.

[0167] Figure 22 is depicted as being able to be performed by a control circuit (such as Figure 13 the control circuit 1932 shown in and / or Figure 14Logic flow diagram of process 13210 performed by the control circuit (shown in ) for controlling a motor of a motor system of a surgical instrument system (such as those disclosed herein). The control circuit is configured to initiate a firing speed interrogation sequence of a firing member within a pre-compression zone 13211. The control circuit is configured to perform 13212 one or more sensing actions within the pre-compression zone. During the one or more sensing actions, the control circuit is configured to monitor 13213 one or more response parameters of the motor system. The control circuit is configured to reverse 13214 the firing member to a starting position. The control circuit is configured to perform 13215 one or more additional sensing actions within the pre-compression zone. During the one or more additional sensing actions, the control circuit is configured to monitor 13216 one or more response parameters of the motor system. In at least one case, the firing speed interrogation sequence occurs one or more times, such as for example 3 times, 5 times, and / or about 10 times. In at least one case, the firing speed interrogation sequence occurs a predetermined number of times before selecting a firing speed for a subsequent staple firing stroke. Nevertheless, the control circuit is configured to select 13217 a firing speed profile based on the monitored parameters of the periodic sensing actions performed within the pre-compression zone. In at least one case, the firing speed interrogation sequence occurs, for example, within a clamping zone of the firing member and / or after clamping but before firing any staples.

[0168] In at least one case, cycling the firing member in the above manner during the pre-compression phase can also help identify and understand the process of tissue stabilization. For example, if relatively thick tissue is clamped, the firing member cycled in the manner described herein during the pre-compression phase may show that the motor system is approaching, at, and / or above maximum or optimal capacity prior to firing, for example indicating that relatively thick tissue has been clamped and / or indicating that the relatively thick tissue clamped within the end effector takes longer than expected to stabilize. Various parameters of the motor system can be adjusted based on information collected from the initial movement of the firing member during the pre-compression phase. For example, if thick tissue is clamped within the end effector and determined during the pre-compression phase, the parameters and variables of the sensing actions and / or responses can be adjusted, for example, based on the detection of thick tissue during the pre-compression phase. Information collected from the initial movement of the firing member during the pre-compression phase can also be used to determine how long to allow the tissue to stabilize. See Figure 22 , for example, during the sensing actions and the additional sensing actions, information is collected from monitoring 13213 and monitoring 13216 one or more parameters of the motor system.

[0169] In various situations, imperceptible sensing or querying actions are skipped, and reactive or functional actions are performed to determine if there is excess capacity within the motor system. For example, the speed of the motor can be increased by a perceptible amount. Similar to the sensing actions discussed above, the motor control circuit can determine if the perceptible increased speed has been reached by measuring the actual speed obtained in response to the perceptible speed increase. In at least one case, once it is determined that the target speed cannot be reached, the functional action configured to be able to increase the speed of the motor until it is determined that the target speed cannot be reached is terminated. For example, the functional action can gradually increase the speed of the motor in a stepwise and / or continuous manner until the actual speed of the motor deviates from the target speed by less than a differential threshold.

[0170] In at least one case, sensing actions and / or functional actions are performed throughout the firing stroke to strive to maintain the optimal operating efficiency of the motor system. For example, the speed of the firing motor can be constantly slowed and accelerated while the relative capacity of the motor system is constantly monitored and evaluated. In at least one case, a limited number of sensing actions and / or functional actions are performed. In at least one case, the limited number is set, for example, by the user and / or the motor control program. The limited number can be based, for example, on the lifespan of the instrument and / or the motor system, the type of instrument, the function actuated by the motor system, or any suitable parameter.

[0171] Figure 23 FIG. 13090 is a graph showing the clamping stroke and the firing stroke of a surgical instrument system. In at least one case, the clamping stroke and the firing stroke are performed by separate drive members. In at least one case, the clamping stroke and the firing stroke are performed by a single drive member. The firing force 13091 for the firing stroke is shown. Also shown are the target speed 13093 and the actual speed 13092 of the firing member during the firing stroke. In addition to the above, the PWM signal 13094 of the motor is also shown. As can be seen in FIG. 13090, the PWM signal 13094 is incrementally increased 13095, for example, by increasing the duty cycle. In at least one case, it is determined that there is excess capacity within the motor system to reach speed V2, at which point a functional action 13096 is taken to increase the speed of the motor to speed V2. This is achieved by increasing 13097 the PWM signal. In at least one case, the PWM signal is increased to the duty cycle 13097.

[0172] In at least one case, sensing actions are also performed while retracting the firing member through the end effector. Such an arrangement can provide a faster retraction stroke without increasing the speed of the motor to or beyond its maximum or optimal capacity, which increase can lead to instability of the motor system.

[0173] Figure 24It is a graph 13100 depicting the target speed 13101 and the actual speed 13102 of the nailing stroke of a motor system including a plurality of discrete interrogation actions 13103. In at least one case, each interrogation action 13103 includes the same magnitude of change, such as, for example, the same speed increase. In some cases, the step size may increase linearly between discrete interrogations. In other cases, the step size may vary between discrete interrogations.

[0174] In the illustrated example, the plurality of discrete interrogations 13103 includes a final interrogation action 13104. During the nailing stroke, the speed of the motor increases incrementally during each interrogation action 13103. At the final interrogation 13104, the expected response of the actual speed 13102 is not achieved, and thus the motor control circuit returns the speed of the motor to the target speed of the previous interrogation action 13103. In at least one example, when the difference between the actual speed 13102 and the set target speed exceeds a predetermined threshold, the motor control circuit determines that the response is not achieved.

[0175] Figure 25 It is a graph 13110 depicting the target speed 13111 and the actual speed 13112 of the nailing stroke of a motor system including a plurality of discrete interrogation actions 13113. In at least one case, the magnitude of each interrogation action 13113 decreases with each subsequent action. For example, for each subsequent interrogation action 13113, the increase in the motor speed decreases. In at least one case, the decrease in the magnitude of each interrogation action 13113 corresponds to determining the relative capacity of the motor system by the actual speed or response distribution 13112 relative to the target speed or target distribution 13111. For example, if the actual speed 13112 begins to deviate further from the expected speed with each interrogation action 13113 at a certain moment, using continuously smaller interrogation actions can help achieve maximum efficiency by reducing overshoot. In at least one case, the rate at which the magnitude of each interrogation action 13113 decreases is selected by the motor control circuit based on the rate of deviation of the actual speed 13112 relative to the target speed 13111. The plurality of discrete interrogation actions 13113 includes a final action 13114. At the final action 13114, the target speed 13111 is not achieved, and thus the motor control circuit returns the speed of the motor to the target speed of the previous interrogation action 13113.

[0176] Figure 26FIG. 13120 is a graph depicting the target speed 13121 and the actual speed 13123 of a firing stroke of a motor system, including a target profile and a response action 13124, the target profile including a logarithmic increase of a control metric (such as, for example, speed or PWM) of the firing stroke. For example, increasing the control metric of the motor logarithmically (e.g., PWM or speed) can reduce overshoot. As can be seen in graph 13120, the target speed 13121 remains constant for a period of time after a logarithmic interrogation. In at least one case, the motor control circuit can keep the target speed 13121 constant when determining that a threshold deviation between the target speed 13121 and the actual speed 13123 has been reached. For example, this period of time can provide the motor system time to stabilize or overcome an unexpected portion of the tissue, thus giving the actual speed 13123 time to stabilize. In at least one case, the actual speed 13123 never recovers, and the response action 13124 is initiated. In at least one case, the actual speed 13123 recovers to at least a certain extent, and the motor system restarts the interrogation of the motor system and continues to increase the speed of the motor. During the response action 13124, the target speed 13121 is decreased by a predefined amount and / or returned to a previous target speed threshold. In at least one case, the magnitude of the speed decrease at the response action 13124 is based on the magnitude of the deviation between the target speed 13121 and the actual speed 13123. In at least one case, increasing the speed of the motor logarithmically to interrogate the relative capacity of the motor system can increase efficiency and reduce the amount of deviation between the actual speed and the target speed.

[0177] Figure 27 FIG. 13130 is a graph showing the clamping stroke and the firing stroke of a surgical instrument system. In at least one case, the clamping stroke and the firing stroke are performed by separate drive members. In at least one case, the clamping stroke and the firing stroke are performed by a single drive member. The firing force for the firing stroke as well as the closing stroke and the closing load are shown. Three different scenarios for interrogating the motor system driving the firing member are shown. In Scenario One, the percentage PWM signal of the motor increases in discrete linear steps 13132, the discrete linear steps including the same magnitude of speed increase for each step, resulting in a linearly increasing firing member speed 13131. In Scenario Two, the percentage PWM signal of the motor increases in discrete steps 13134; however, the magnitude of each speed increase decreases with each subsequent step, resulting in a logarithmically increasing firing member speed 13133. In Scenario Three, the percentage PWM signal of the motor increases logarithmically 13136, resulting in a logarithmically increasing firing member speed 13135.

[0178] Figure 28It is a graph 13140 depicting the primary sensory metric 13141 and the secondary sensory metric 13142. In at least one case, the primary sensory metric 13141 is similar to other metrics disclosed herein. For example, the primary sensory metric 13141 involves incrementally increasing the target speed of the motor, monitoring the actual speed of the motor, and, for example, when it is detected that the actual speed of the motor deviates from the target speed by more than a predetermined threshold percentage, the motor control circuit returns the speed of the motor to the target speed of the previously successful sensory action. In at least one case, the motor control circuit selects a new target speed based on the failed sensory action, which is different from the target speed of the previously successful sensory action, but, for example, based on the rate at which the motor deviates from the target speed over time. The secondary sensory metric 13142 is used by the motor control circuit as a redundancy, for example, to enhance the detection output of the primary sensory metric 13141. For example, the PWM percentage signal 13143 of the motor can be monitored, and when it is determined that the PWM percentage signal 13143 exceeds the predetermined threshold 13144 of 13145, the motor control circuit determines that the motor system is at or above capacity. In this case, this determination is consistent with the determination made within the primary sensory metric 13141. Further adjustments to the motor speed can be made based on both the primary sensory metric 13141 and the secondary sensory metric 13142. In at least one case, the PWM percentage signal 13143 is obtained by converting one or more analog output parameters, such as, for example, the motor speed, into a digital PWM signal.

[0179] Figure 29 It is a graph 13160 of an exemplary nailing stroke performed by the motor system, showing the target speed 13161, the actual speed 13162, and the pulse width modulation signal 13163 of the motor of the motor system. As can be seen in graph 13160, the motor system performs a sensory action or interrogation action 13164 to attempt to increase the speed of the motor within the capacity limits of the motor system. For example, when the actual speed 13162 deviates from the target speed 1361 by more than a predetermined threshold, the sensory action 13164 ends.

[0180] In at least one instance, for example, the pulse width modulation signal 13163 is increased in an attempt to maintain the motor speed through a thick slice of tissue. After passing through the thick slice of tissue, the PWM signal 13163 decreases, resulting in a decrease 13165 in speed 13162. At this time, a time delay and / or a lockout period may be set by the motor system to, for example, prevent the motor system from initiating additional sensing actions. After the time delay and / or lockout period, the motor system may resume interrogating the relative capacity of the motor system in an effort to achieve an optimum efficiency speed. For example, such an arrangement may allow for a locally optimum speed throughout the length of the staple firing stroke. For example, the cutting member may encounter a thick slice of tissue, but only for a certain length of the staple firing stroke. The tissue may be thinner after the thick slice, and thus the capacity to increase the speed of the firing stroke may increase after the cutting member has passed through the thick slice of tissue. At this time, the motor system may restart the interrogation sequence in an effort to maximize the speed of the motor along the entire length of the staple firing stroke. In at least one instance, the interrogation sequence initiated after the lockout or time delay may vary in terms of time length and magnitude compared to the interrogation sequence that occurred prior to the lockout or time delay.

[0181] Figure 30 FIG. 13170 is a graph of a staple firing stroke performed by a motor system including a motor and a firing member configured to be actuated by the motor. A closed load and a closed stroke are shown. Also shown is the firing force 13171 for the firing member. As can be seen from the firing force 13171 graph, the force to fire the firing member increases 13172 between t1, t2, t3, and t4 and decreases 13173 at t4. The actual speed 13176 of the firing member as well as the target speed 13175 of the firing member are also shown. In at least one instance, the actual speed includes the actual speed of the motor. In addition to the above, the PWM percentage 13177 is also depicted. Between t1 and t2, the relative capacity of the motor system is interrogated by increasing the PWM percentage 13177 in discrete steps 13178 in an effort to reach a set speed. The set speed is reached at t2. During the time period between t1 and t2, the actual speed 13176 of the firing member does not deviate from the target speed 13175.

[0182] At t2, the PWM percentage 13177 remains constant, and the actual speed 13176 begins to deviate from the target speed 13175. At this time, the motor system attempts to compensate by sharply increasing the PWM percentage 13177 to reach the set speed again. In at least one case, the PWM percentage 13177 does not change 13179 between t2 and t3 because the actual speed 13176 begins to deviate from the target speed 13175. As also visible in graph 13170, the firing force 13171 for the firing member increases between t2 and t3, which can cause a deviation between the actual speed 13176 and the target speed 13175. In at least one case, the increase in the firing force can be attributed to a change in tissue thickness. At time t3, the motor control circuit takes a functional action 13180, where the PWM percentage 13177 is sharply increased in an effort to increase the speed 13176 of the motor and / or the firing member, e.g., back to the previously reached set target speed. Between time t3 and time t4, the speed 13176 of the firing member increases, and when the speed 13176 has not yet reached the new target speed 13175 of V2, the firing member has reached and exceeded the previously reached set speed. In at least one case, the inability to obtain the new speed of V2 is the result of another increase in the firing force 13171 experienced by the firing member between t3 and t4. Since the target speed V2 is not reached, but the previously reached set speed has been reached again, the PWM percentage 13177 is slightly decreased 13181 (not back to the PWM percentage 13177 used between t2 and t3) to achieve optimal efficiency and maintain the optimal speed. At time t4, the PWM percentage decreases and can be triggered by a decrease in the firing force at t4. For example, between time t4 and time t5, the actual speed 13176 and the target speed 13175 are equal or at least do not deviate by more than a threshold deviation. At this time, the PWM percentage 13177 remains constant until the end of the stapling stroke. In at least one case, the set speed is modified during the stapling stroke based on the motor system's response to a sharp increase in the duty cycle. In at least one case, the set speed decreases after a sharp increase in the duty cycle. In at least one case, the set speed increases after a sharp increase in the duty cycle.

[0183] In at least one case, one or more predetermined shift thresholds are utilized during a sensing operation. For example, as the motor speed increases in an effort to determine if there is available capacity for increasing the speed, the relative capacity of the motor system can be defined as a quantifiable amount. For example, it can be determined that the motor system is operating at 50% capacity and has 50% available capacity. A first predetermined shift threshold can be set to a first percentage of the available capacity, for example to set a threshold for determining a target speed that can be set greater than the current speed. Thus, as the speed of the motor increases and the relative capacity of the motor system is determined, once it is determined that there is the first percentage of available capacity or more available capacity, the motor control signal can be adjusted to shift the motor speed to an increased target speed. In at least one case, the system performs another sensing operation and, if there is still the first percentage of available capacity or more, the speed of the motor is increased again. In at least one case, additional predetermined shift thresholds are set to determine when to shift the speed of the motor to a decreased new speed. For example, 5% available capacity can be set as the second predetermined shift threshold. Thus, when 5% available capacity or less is detected, the motor control circuit can decrease the motor speed to a decreased new speed. As discussed herein, the percentage deviation from the threshold can be used to determine the magnitude of the new speed. For example, if there is 75% relative capacity in a system with a 25% first predetermined shift threshold, the relatively large availability of capacity can cause the motor control circuit to increase the magnitude of the motor speed increase accordingly. On the other hand, if there is 0% capacity and / or the motor system is beyond the maximum capacity (e.g., 0%), a larger magnitude of speed decrease can be utilized to more appropriately adjust the motor towards an optimal operating speed, for example in response to being at or beyond the maximum motor capacity.

[0184] Figure 31Graph 13180 of an exemplary nail driving stroke performed by a motor system, showing a target speed 13181 and an actual speed 13182. In at least one case, the motor control circuit is configured to be able to reduce the motor speed when it determines that a threshold deviation between the actual speed 13182 and the target speed 13181 is detected. In at least one case, the rate of increase and / or decrease of the deviation between the actual speed 13182 and the target speed 13181 is monitored, and when a change speed threshold is reached (e.g., the actual speed 13182 drops too fast relative to the target speed 13181), speed adjustment is made through one or more reactions. As can be seen in graph 13180, the motor system starts 13191 the firing sequence and sets the target speed 13181 to a first target speed. At a certain point in time, the motor system then performs a sensing action 13192 by increasing the target speed 13182 of the motor to a second target speed over a specific period of time, during which the actual speed 13181 and / or the percentage deviation between the actual speed 13182 and the second target speed is monitored. When it is determined that the actual speed 13182 drops below a predetermined threshold and / or when it is determined that the threshold deviation between the actual speed 13182 and the target speed 13181 is reached or exceeded, a reduction reaction 13194 is initiated. As can be seen in graph 13180, the actual speed 13182 gradually decreases 13193 after attempting the second target speed. In at least one case, the rate at which the actual speed 13182 decreases can trigger a reduction reaction. Nevertheless, the motor system reduces the target speed 13181 of the motor to one or more new reduced target speeds relative to the second target speed. In at least one case, the target speed of the motor is gradually reduced. At this time, additional monitoring of the actual speed relative to the new target speed can be performed in order to analyze the impact of the reduction reaction on the relative capacity of the motor and to determine whether further adjustment is needed.

[0185] Figure 32 is a logic flow diagram depicting a process 13200 that can be performed by a control circuit (such as Figure 13 control circuit 1932 shown in Figure 14 and / or the control circuit shown in), the control circuit being configured, for example, to be able to interrogate the motor system to determine whether there is excess capacity within the motor system, for example, during a firing sequence of a driveline. In this case, the control circuit controls the firing sequence. The control circuit starts 13201 the firing sequence, increases 13202 the target speed of the motor to a first target speed over a certain period of time, measures 13203 the actual speed of the motor during that period of time, compares 13204 the measured actual speed with the first target speed, determines 13205 the relative capacity of the motor system based on the comparison 13204, and sets 13206 a new speed based on the determined 13205 relative capacity. In at least one case, the new speed is equal to the first target speed.

[0186] As discussed herein, the motor control circuit may perform interrogation actions and / or responses during a closing stroke and / or a firing stroke. The motor control circuit may also measure the speed of the motor in response to an increase in the target speed during any suitable time period. The time period for each interrogation or sensing action may be predetermined and / or preselected. The time period for each interrogation action may vary from one interrogation action to the next. Comparing the target speed to the actual speed may involve analyzing the percentage deviation between the target speed and the actual speed. In at least one case, a fixed threshold speed is utilized to determine whether to perform an additional interrogation action or set a new speed. A pause may be used between interrogation actions. In at least one case, a pause is not used. In at least one case, a pause may include a time period during which no interrogation actions are performed. In at least one case, a pause may include, for example, a pause in the movement of the firing member between interrogation actions. In at least one case, the motor system automatically interrogates the relative capacity of the motor system during the entire stroke of the powertrain in an effort to maximize the efficiency of the motor system throughout the stroke. In such a case, a series of speed increases and decreases may occur throughout the stroke.

[0187] The control circuits disclosed herein may employ any of the steps and / or actions disclosed herein. The process may be performed by any suitable component (such as Figure 13 and Figure 14 the components disclosed in). The processes disclosed herein may be performed using any suitable powertrain (such as those disclosed herein in Figures 1 to 12 ). The processes that may be performed by the control circuit may include any suitable additional steps and / or actions, cancel one or more steps and / or actions, and / or modify one or more steps and / or actions according to any of the scenarios discussed herein.

[0188] As discussed herein, the motor control circuit can be configured to be capable of performing any combination and any number of sensing actions, interrogation actions, and / or functional actions, etc., in an effort to control, for example, the speed of a motor of a motor system during a drive stroke of a driveline of the motor system. In at least one case, these actions can be referred to as speed control actions. While speed is one variable that can be controlled, adjusted, and / or monitored during these actions, any suitable variable can be used, such as, for example, those disclosed herein. In at least one case, the result of each of these actions can be used to modify future actions and / or trigger other events, as detailed below. Functional actions can be automatically triggered by one or more events and / or manually triggered by a user. For example, a user can manually trigger an increase in speed during a drive stroke, at which time the motor control circuit can be configured to be capable of increasing the target speed of the motor and determining whether the target speed can be and / or has been reached. The reaction to the manually increased speed can include any suitable reaction, such as those disclosed herein.

[0189] In at least one case, if one or more conditions are met due to one or more previous actions, further speed adjustment and / or speed control actions can be stopped. The effects or results of the previous actions can be continuously monitored. In at least one case, the effect or result includes whether the target speed of the previous action has been reached or not reached. For example, not reaching the target speed can be considered a failed action. In at least one case, the effect or result includes whether the target speed of the previous action has been reached within a predetermined deviation percentage, and / or the magnitude of the failure and / or success of the previous action. In at least one case, for example, further actions can be stopped temporarily and / or permanently. In at least one case, further actions for automatically controlling the motor speed can be reactivated automatically and / or manually. In at least one case, for example, when a new firing stroke is initiated, the further actions are automatically reactivated.

[0190] In various cases, based on the effects or results of previous speed control actions, the motor control circuit can be configured to be capable of preventing further speed control actions from occurring, whether automatically and / or manually triggered, for a predetermined period of time. In at least one case, the motor control circuit is configured to be capable of preventing further speed control actions from occurring automatically rather than manually or manually rather than automatically.

[0191] Preventing further speed control actions or motor control adjustment actions from occurring can prevent oscillations and / or hysteresis. For example, in the case where there is no pause or lock period after a previous action, the motor control circuit can accidentally perform an undesired adjustment, for example, based on a default control algorithm. In at least one case, the motor control circuit is configured to be capable of locking the occurrence of any adjustment actions during a lock period after a failed action (e.g., not reaching the target speed) occurs. Figure 33FIG. 16000 shows a graph depicting an example strike stroke performed by a motor control circuit of a motor system, showing a target speed 16001 and an actual monitored speed 16002. As can be seen in graph 16000, the motor control circuit performs a sensing or functional action 16003 to attempt to increase the motor speed to a new target speed 16001. The actual speed 16002 is monitored and it is determined that there is no capacity to run the motor system at the new target speed. The target speed 16001 reverts to the speed before the new target speed. As disclosed herein, the success of a sensing action may refer to, for example, the actual speed reaching a desired percentage of the new target speed. The failure of a sensing action may refer to the actual speed not reaching the desired percentage of the new target speed. In at least one case, a successful sensing action indicates the presence of excess capacity to run the motor system at the new target speed. In at least one case, a failed sensing action indicates the absence of excess capacity to run the motor system at the new target speed.

[0192] As Figure 33 can be seen, the motor control circuit employs a lockout period 16004 that is configured to prevent any subsequent actions from occurring during the lockout period 16004. In at least one case, the lockout period 16004 is predefined. In at least one case, the magnitude of the lockout period depends on one or more variables of the result of a previously failed sensing action. For example, if the magnitude of a previous sensing action fails by a large margin, the lockout period may be longer compared to a case where the sensing action fails by a smaller margin. As discussed herein, the magnitude of failure can be measured as a percentage deviation. A deviation threshold can be utilized to determine the length of the lockout period. After the lockout period, one or more additional actions 16005 can be performed. In at least one case, the number and / or magnitude of the additional actions that can be performed are restricted based on the failed sensing action, where if no failed sensing action occurs, the additional actions may not be restricted in any way. In at least one case, for example, the additional actions are not restricted regardless of whether a failed sensing action occurs.

[0193] In at least one case, the length of the timeout or lockout period depends on the current speed of the motor. For example, the magnitude of the current speed of the motor can be used to determine the magnitude of the lockout period. In at least one case, a faster speed triggers a longer timeout period, while a slower speed triggers a shorter lockout period. In at least one case, a faster speed triggers a shorter timeout period, while a slower speed triggers a longer lockout period. In various cases, the success status of one or more previous speed control actions triggers timeout periods of different lengths. For example, for successful and unsuccessful or failed speed control actions, lockout periods can be employed during the drive stroke. In such a case, the lockout period for a successful speed control action can be shorter compared to the lockout time for a failed speed control action.

[0194] In at least one case, the prevention or lockout period can prevent an unintentional reshift immediately following an intentional functional action of the motor control circuit. For example, a user may select to increase the motor speed from a first speed to a second speed. The motor control circuit may determine that the second speed is not achieved. However, instead of reverting to the first speed, the motor control circuit may employ a lockout period as a result of the manually input speed change, so as not to automatically cancel the speed change desired by the user, for example. In at least one case, the motor control circuit is configured to be able to cancel the speed change desired by the user, regardless of the fact of the manually input speed change by the user. In at least one case, further intentional manual speed change inputs are prohibited during the lockout period.

[0195] In at least one case, the motor control circuit is configured to be able to disable the automatic speed control after triggering a predetermined number of lockout periods during the firing stroke. Such an arrangement can prevent continuous adjustment of the motor system when certain adjustments always result in failed actions.

[0196] In at least one case, the motor control circuit employs a lockout distance period. For example, after a failed action occurs, the motor control circuit is configured to be able to prevent any speed control action from occurring during a predefined distance of the drive stroke. In other words, for example, when it is determined that the firing member is within the lockout zone between position A and position B, further adjustment actions are prohibited. For example, the motor control circuit can prevent any speed control action or adjustment from occurring within the next 10 mm after a previously failed action is completed. For example, the magnitude of the lockout distance can vary based on the magnitude of the failed action. For example, if the actual speed of the motor deviates from the target speed by more than a threshold deviation percentage, the lockout distance can be set to a first distance. If the actual speed of the motor deviates from the target speed by less than the threshold deviation percentage but still fails, the lockout distance can be set to a second distance that is less than the first distance. In at least one case, the second distance is half of the first distance.

[0197] In at least one case, speed adjustment actions are prohibited before the firing stroke. In at least one case, speed adjustment actions are prohibited between the unfired position of the firing member and the failure lock position of the firing member. The failure lock position may be the position when and / or just after the firing member has passed through a lock of the surgical stapling instrument (such as, for example, a no-cartridge lock and / or a waste-cartridge lock). In at least one case, when the firing member is positioned within the region immediately adjacent to the end of the firing stroke and / or before the end of the staple cartridge, speed adjustment is prohibited.

[0198] The firing member discussed herein may refer to any suitable component, such as, for example, the I-beam of the firing shaft and / or any portion thereof, a slider configured to be able to eject staples from the staple cartridge and / or any portion thereof, the firing shaft and / or any portion thereof, the firing rod and / or any portion thereof, and / or any combination of any portion of the firing drive train.

[0199] In at least one case, the average actual speed monitored during the period of a sensing, functional, and / or interrogation action may be used to determine whether the target speed is reached. In at least one case, the maximum actual speed monitored during the period of a sensing, functional, and / or interrogation action may be used to determine whether the target speed is reached. In at least one case, the minimum actual speed monitored during the period of a sensing, functional, and / or interrogation action may be used to determine whether the target speed is reached. In at least one case, any combination of the foregoing metrics may be used to determine whether the target speed is reached. A predetermined percentage deviation may be stored in memory and may be accessed when determining whether the target speed is reached. The predetermined percentage deviation may vary for different types, such as, for example, the length and / or staple height of the staple cartridge being fired.

[0200] In various cases, the motor control circuit is configured to be able to stop or prohibit motor control parameter adjustment (such as, for example, PID controller parameters) during a locking period and / or a locking distance. In at least one case, the PID controller parameter adjustment may be frozen for a period the same as or different from the predefined locking period. In at least one case, the thresholds and / or conditions that the motor control circuit needs to meet to change one or more PID controller parameters during the drive stroke may be widened or relaxed, for example, to minimize the number of apparent or perceivable speed readjustments after a failure action. For example, the error required to trigger an adjustment of one or more PID controller parameters after a failure action may be greater than the error required to trigger an adjustment before a failure action.

[0201] In various situations, the motor control circuit is configured to be able to learn over time and adjust future speed control actions for future drive strokes based on previous drive stroke data. In at least one situation, certain outputs monitored during a drive stroke can be used to identify opportunities to update the weights of a feedforward network. The network weights can include thresholds. The thresholds can indicate out-of-bounds conditions.

[0202] In at least one situation, the motor control circuit is configured to be able to return the motor system to the last known good state. This can be triggered, for example, by a failed action. In at least one situation, the last known good state includes a state where the motor system is operating adequately and is not near and / or at full capacity.

[0203] In at least one situation, the motor control circuit is configured to be able to perform speed control actions during firing member advancement and / or firing member retraction.

[0204] In various situations, the motor control circuit is configured to be able to change the speed control algorithm, for example, in response to an event and / or an accumulating sequence of triggers. In at least one situation, a predetermined number of failed actions must occur, failed actions must occur at a predetermined frequency, and / or a predetermined number of failed actions must fail at a specific percentage before the motor control circuit reacts. Any suitable reaction can occur, such as those disclosed herein. For example, parameters of further actions can be adjusted, a lockout period and / or a lockout zone can be employed, PID motor controller parameters can be adjusted, etc. In at least one situation, in addition to a predetermined single event, a sequence of events must occur for the motor control circuit to react. Such an arrangement can provide better situation-specific control of the motor system during a firing stroke. For example, during a firing stroke, a predetermined number of sensory actions may fail. While this alone will not trigger further action, this in combination with a single event (such as, for example, a single sensory action failing below a certain threshold) can trigger a cooling period or a pause. In addition to larger failed actions, a sequence of failed actions can indicate that the motor is struggling to perform the firing stroke to begin with, and upon detection of a larger failed action, indicates to the motor control circuit that the motor may have overheated and / or is operating beyond its maximum or optimal capacity. For example, automatic activation of a cooling period can allow the tissue to relax and the motor to cool.

[0205] In various situations, the motor control circuit is configured to be able to utilize the events of previous firings of the instrument to adjust and / or alter the speed control algorithm for subsequent firings. For example, a first cartridge may be used with the instrument, and during the firing of the first cartridge, data is collected regarding the results of various speed control actions performed, for example, during the firing stroke of the first cartridge. The motor control circuit may then be configured to be able to adjust one or more parameters of the firing stroke of a second cartridge to be fired based on the data collected regarding the results of the various speed control actions performed during the firing of the first cartridge. By monitoring the events of each staple cartridge firing and optimizing each subsequent firing based on the performance of the previous firing, such an arrangement may allow the motor control circuit of a particular motor system to operate more effectively between multiple different staple cartridges.

[0206] An example of a motor control circuit that utilizes data from multiple different firings is discussed below. The motor system of a surgical instrument fires two different staple cartridges. At the 50 mm position, the motor control circuit detects an irregularity in the firing stroke. In at least one case, a speed difference is detected at the 50 mm mark. In at least one case, a displacement difference between the motor and the firing member is detected at the 50 mm mark. The motor control circuit is configured to be able to adjust any subsequent firing of the other staple cartridge to increase the motor speed prior to the 50 mm mark (such as, for example, at the 45 mm mark). This increase in speed can ensure that for any subsequent firing of the instrument, the motor system does not lag and / or compensate for the known repeated irregularities at the 50 mm mark of the instrument. In at least one case, the motor control circuit is configured to be able to perform a rapid burst at and / or near the 50 mm mark. In at least one case, the motor control circuit is configured to be able to send an additional burst pulse of power to the motor just prior to the 50 mm mark and only for a short period of time. In at least one case, the motor control circuit is configured to be able to adjust the speed control algorithm for subsequent firings to attempt to maintain a constant speed through the 50 mm mark and eliminate the irregular stroke. Such a configuration can overcome the recurring stroke irregularities between firings that may distract the user, cause abnormal cutting of tissue, and / or result in unpredictable staple formation.

[0207] In various cases, a predetermined level of a repeatability threshold must be met before speed control adjustments are made to subsequent firing strokes. For example, a motor control circuit may determine stroke irregularities or anomalies at the 30 mm mark during the advancement and retraction strokes. This may indicate a location where interface components such as, for example, I-beams and channels and / or anvil have a tighter interference. Such tighter interference may be caused by tissue intrusion and / or manufacturing anomalies, for example, tissue intrusion and / or manufacturing anomalies increasing the firing force at that location. Due to such stroke irregularities, staple formation and / or tissue cutting may not be predictable. In at least one case, the motor control circuit adjusts the parameters for all subsequent strokes at that location to reduce the firing force at that location, for example, in an effort to form staples and / or cut tissue in a more predictable manner. In at least one case, the adjusted parameters may revert to normal after passing this location (e.g., during advancement and / or during retraction). In at least one case, the motor control circuit is configured to be able to predict a previously detected stroke irregularity during subsequent strokes by adjusting the parameters of the subsequent strokes, specifically looking for stroke irregularities, but not taking any action unless a newly monitored irregularity is detected. In at least one case, spikes in force are monitored and associated with stroke irregularities.

[0208] In various cases, a series of stroke irregularities are detectable and used to adjust the motor control of the drive stroke. For example, whenever a staple leg contacts the anvil to be formed, the motor control circuit may detect multiple force spikes within the motor system. In at least one case, this initial contact may result in the largest spike within the motor system during staple formation, which is detectable and prominent among the multiple force spikes of the firing stroke. This spike may be detected by the motor control circuit as the highest peak force during the formation of each staple, each staple including a known position relative to the firing stroke. In at least one case, if the spikes detected for one or more staples (a series of stroke irregularities) exceed a predetermined threshold or a predetermined threshold distribution, the motor control circuit may perform one or more speed control actions to reduce the force spike for each leg-anvil contact event. In at least one case, a spike exceeding the threshold during initial leg-anvil contact may indicate that the leg is not striking the anvil at the expected and / or desired location. Such spikes may indicate that tissue is being gathered by the knife and pushing the staple leg distally relative to the anvil, resulting in the tip of the staple missing the target pit location and thus increasing the force of the fired staple and also causing, for example, staple deformation. Reducing the speed of the motor to increase the likelihood of the staple spike contacting its intended target location may reduce the firing force and increase the likelihood of proper staple formation.

[0209] In at least one case, the motor control circuit is configured to be able to monitor the number of failed / successful speed control actions, and once a predetermined number of failed / successful speed control actions occur, adjust the magnitude of subsequent speed control actions. For example, when a predetermined number of failed actions occur, the motor control circuit may set a limit on the target speed of subsequent speed control actions. In at least one case, the user may attempt to increase the motor speed by a certain amount; however, the motor control circuit may set a target speed threshold that cannot be automatically and / or manually exceeded. If the user attempts to increase the motor speed to exceed the target speed threshold that is a limit triggered by a series of previous failed speed control actions, the motor control circuit may automatically lower the actual target speed to the threshold target speed and attempt to increase the motor speed to the threshold target speed. In at least one case, for example, such a configuration may prevent the user and / or the motor control circuit from increasing the speed of a motor that is already laborious beyond a specific threshold based on multiple previous failed speed increase actions. In at least one case, after a predetermined number of successful speed control actions are performed at the newly set limit threshold target speed, the limit threshold target speed may be deleted or cancelled. In at least one case, the limit threshold target speed cannot be cancelled and / or deleted until a new staple cartridge is installed and / or a new firing stroke is performed. In at least one case, for this surgical instrument, the limit threshold target speed is never cancelled.

[0210] In various cases, the motor control circuit is configured to be able to monitor the pattern of the results of speed control actions, and based on this pattern, adjust one or more future speed control actions based on the monitored pattern. For example, during the first firing, multiple failed actions may occur. If the degree of failure of each subsequent failed action increases to correspond to a predetermined pattern of increasing failure, the motor control circuit may detect the predetermined pattern of increasing failure and adjust subsequent firings accordingly. In at least one case, adjust the magnitude and / or frequency of the speed control actions for subsequent firings. In at least one case, the motor control circuit is configured to be able to set a limit on the number of subsequent firings allowed for the surgical instrument based on the detected predetermined pattern of increasing failure. In at least one case, a lockout period is employed, and the magnitude or length of the lockout period may be increased based on the detected predetermined pattern of increasing failure. Such a configuration may provide a certain amount of time for the motor system to reduce its power consumption and / or mechanical energy burden.

[0211] In various situations, the motor control circuit is configured to be able to adjust the frequency of subsequent sense actions based on a predetermined cumulative amount of detected sense action failures. For example, after detecting a predetermined amount of sense action failures, the motor control circuit may reduce the frequency of automatically and / or manually performing speed control adjustments for remaining and / or subsequent firings. In at least one situation, the motor control circuit is configured to be able to adjust the definition of a failed action for subsequent or remaining firings based on a predetermined cumulative amount of detected sense action failures. For example, the motor control circuit may increase the threshold required for a sense action to be considered successful.

[0212] Figure 34 is a logic flow diagram depicting a process 16010 that may be performed by a motor control circuit (such as Figure 13 the control circuit 1932 shown in Figure 14 and / or the control circuit shown in

[0213] Figure 35 is a logic flow diagram depicting a process 16010 that may be performed by a motor control circuit (such as Figure 13 the control circuit 1932 shown in Figure 14A logic flow diagram of process 16020 performed by a motor control circuit (such as the control circuit shown in [reference]) and used, for example, in a surgical instrument system (such as those described herein). The motor control circuit is configured to be able to actuate 16021 a firing member through a first staple firing stroke, perform 16022 a first sensing action during the first staple firing stroke, and monitor 16023 the result of the first sensing action. The motor control circuit is further configured to be able to actuate 16024 the firing member through a second staple firing stroke, adjust 16025 the parameters of a second sensing action based on the monitored result of the first sensing action, and actuate 16026 the firing member through the second staple firing stroke. The motor control circuit is further configured to be able to perform 16027 a subsequent sensing action during the second staple firing stroke using the adjusted parameters.

[0214] Figure 36 is a logic flow diagram of process 16030 that may be performed by a motor control circuit (such as Figure 13 the control circuit 1932 shown in [reference] and / or Figure 14 the control circuit shown in [reference]) and used, for example, in a surgical instrument system (such as those described herein). The motor control circuit is configured to be able to actuate 16031 a firing member through a firing stroke, perform 16032 a plurality of first sensing actions during the firing stroke, and monitor 16033 the success status of each of the first sensing actions. The motor control circuit is further configured to be able to adjust 16034 one or more parameters of one or more subsequent sensing actions based on the monitored success status of each of the first sensing actions. In at least one case, the adjustment is based on how many previous sensing actions have failed compared to success. In at least one case, the control circuit is further configured to be able to adjust the parameters according to a first adjustment distribution when a threshold number of successful first sensing actions are detected. In at least one case, the threshold number can be automatically determined and / or manually set.

[0215] In various situations, a motor control circuit is utilized to control a motor of a motor system that includes a drive train, such as a firing drive train. In at least one situation, the motor control circuit may operate within a set of adjustable parameters. For example, the motor control circuit may set a minimum speed threshold to a first speed and a maximum speed threshold to a second speed greater than the first speed to initiate a staple firing stroke. These threshold speeds may be adjusted and / or fine-tuned, for example, during the staple firing stroke of the motor system to optimize the operation of the motor system in real-time and / or maximize the efficiency of the motor system within a single drive stroke. Various factors such as, for example, drive train recoil and / or heat loss within the motor may cause the motor system to operate inefficiently. However, adjusting the adjustable parameters during the staple firing stroke may address, mitigate, and / or compensate for issues such as, for example, drive train recoil and / or heat loss within the motor. The magnitude of the adjustment made to these threshold speeds may be based on a variety of factors. For example, any suitable parameter or combination of parameters of the motor system may be monitored. In such a case, the new threshold speeds may be determined based on, for example, the magnitude of the monitored parameter and / or the rate at which the monitored parameter changes over a period of time. In at least one situation, multiple monitored parameters are compared and analyzed to determine an appropriate adjustment to the adjustable parameters.

[0216] In at least one situation, a maximum motor current limit is set by the motor control circuit to limit the amount of electrical current drawn by the motor to a predetermined threshold current. In at least one situation, the predetermined threshold current may vary in different portions of the drive stroke, such as, for example, the staple firing stroke. For example, a first portion of the stroke may include a first threshold current limit and a second portion of the stroke may include a second threshold current limit different from the first threshold current limit. In at least one situation, a lower limit current threshold is utilized at the start of the drive stroke where the drive member may encounter a locked state in order to prevent a relatively large amount of current draw during the locked state, which is detectable based on a small uptick in current and thus does not require, for example, a large amount of electrical current that may unnecessarily overload the system. Such an arrangement may provide some protection to the drive train at the start of the firing stroke. In at least one situation, the threshold current limit for the retraction stroke of the drive member is set relatively high compared to the threshold current limit set for the advancement portion of the stroke in order to ensure that the motor can retract the drive member even if the threshold current limit is reached during the advancement portion of the stroke. This may be because the threshold current limit for the retraction stroke is always greater than the maximum threshold current limit for the advancement stroke. In at least one situation, if the drive member cannot be fully retracted, the jaws of the end effector may become jammed.

[0217] Figure 37FIG. 14000 is a graph depicting various parameters of a motor control algorithm executable by a firing stroke control circuit. Graph 14000 shows a motor torque limit 14001 and a motor current limit 14002 during various stages of use of the surgical instrument system. As can be seen in graph 14000, the torque limit 14001 and the current limit 14002 vary in different parts of the drive stroke. In at least one case, the torque limit 14001 and the current limit 14002 peak during the firing stroke portion of the drive stroke. As discussed herein, the limits 14001, 14002 can be adjusted during the drive stroke based on at least one monitored parameter and at multiple different times throughout the drive stroke to fine-tune the limits 14001, 14002 in real time during the drive stroke.

[0218] In various cases, a duty cycle range for pulse width modulation (PWM) motor control is set by the motor control circuit. In at least one case, the motor duty cycle range is adjusted during the drive stroke based on one or more monitored parameters. Figure 38 A plurality of motor duty cycles 14010 are shown. In at least one case, the motor control circuit employs a 25% minimum duty cycle 14013 such that the motor operates at a duty cycle of at least 25%, and the motor control circuit employs a 75% optimal duty cycle 14012 such that the motor does not operate at a duty cycle exceeding 75%. For example, if the motor control circuit attempts to adjust the speed of the motor such that this would result in a motor duty cycle exceeding 75%, the motor control circuit will determine that the 75% duty cycle threshold will be met and / or exceeded, and thus will not make the adjustment and / or will change the magnitude of the adjustment such that the adjustment will not result in the 75% duty cycle threshold being met and / or exceeded. For example, the optimal duty cycle 14011 can include 50%. In at least one case, the motor control circuit is configured to be able to make any speed adjustment based on the optimal duty cycle 14011. The adjustment of the PWM duty cycle as disclosed herein can be referred to as PWM speed control.

[0219] In various situations, the motor performance curve of the motor is utilized to determine the optimal duty cycle range. In at least one situation, the motor performance curve of the motor is used to set the maximum duty cycle threshold and the minimum duty cycle threshold. The motor performance curve can be used to determine the most effective range of the duty cycle. In at least one situation, the minimum duty cycle limit is set based on the frictional losses and / or inertia characteristics of the driveline in an effort to eliminate jerk, oscillation, and / or vibration of the motor system. In at least one situation, the maximum duty cycle limit is set based on the heat generation of the motor. In addition to the above, older motors may generate more heat over time. In such a case, the maximum duty cycle limit is adjusted for increased heat generation due to, for example, the aging and / or total life of the motor or the degradation of the motor performance over time. For example, setting the maximum duty cycle limit in this manner can consistently minimize heat generation in the motor between strokes and / or even during a single stroke. In at least one situation, the ideal range of the duty cycle limit includes a maximum duty cycle limit of approximately 85% and a minimum duty cycle limit of approximately 25%. In at least one situation, the maximum range of the duty cycle limit includes a maximum duty cycle limit of approximately 90% and a minimum duty cycle limit of approximately 10%.

[0220] In at least one situation, a motor stall condition is set, and once detected, the control circuit can stop the motor after applying a predetermined amount of non-moving torque. For example, if the firing member encounters a tissue sheet that is too thick for the firing member to move, a predetermined amount of non-moving torque may be exceeded, which causes the control circuit to stop the motor when the motor stall condition is met to reduce unexpected heat generation.

[0221] In at least one situation, the motor duty cycle and / or displacement is used to adjust and / or select the target motor speed. For example, a reduced target motor speed may be triggered when the percentage and / or magnitude of the motor duty cycle is relatively high in an attempt to reduce the percentage and / or magnitude of the motor duty cycle. Similarly, for example, an increased target speed may be triggered when the percentage and / or magnitude of the motor duty cycle is relatively low in an attempt to increase the utilization of the motor system.

[0222] Figure 39Depicts a control process 14020 configured to be able to utilize both the monitored duty cycle 14021 and the monitored motor speed and / or the firing member speed such as 14022 as inputs for adjusting the motor speed during the drive stroke. For example, when, for example, the target speed and / or target displacement is not reached, the higher the duty cycle utilization (e.g., closer to the maximum or optimal capacity), the greater the magnitude of the speed reduction adjustment will be in an effort to keep the motor system well within its optimal operating range in response to the missed target. Similarly, in at least one case, if a lower utilization is detected when the target speed or target displacement is missed, the magnitude of the speed increase adjustment is selected based on the determined utilization level of the motor system.

[0223] A non-limiting example of a scenario will be described. The firing member moves at 10 mm / sec, for example, through thick tissue and, for example, successfully meets its displacement and / or speed target. For example, the firing member then encounters a calcified portion of the overly thick tissue and misses one or more displacement targets. At this point, the motor control circuit determines that the motor should be slowed down to allow the tissue to relax, stabilize, loosen, and / or creep in front of the firing member (such as, for example, a cutting blade). In other words, slowing down the firing member reduces some of the load exerted on the firing member by the tightly bundled portion (e.g., the overly thick portion of the tissue). In at least one case, when the displacement target is missed, it may be determined that the duty cycle has also approached 100%, indicating that the motor system may have almost missed its displacement target before the actual detection of the missed displacement target. For example, the system may then slow down the firing member to 150% of its target speed of 10 mm / sec. In a case where the motor control circuit would normally slow down the firing member from 10 mm / sec to 7 mm / sec (a 3 mm / sec expected slowdown action), the motor control circuit determines to slow down the firing member to 5.5 mm / sec (150% - 4.5% of the initial 3 mm / sec expected slowdown action) because the motor system has missed both the displacement target and is at almost 100% utilization when the displacement target is missed.

[0224] In at least one case, the motor control circuit is configured to be able to set a target travel length or displacement target that the firing member is expected to travel during a predetermined period of time. In this case, the motor control circuit using a PID controller may, for example, monitor the error terms (e.g., the proportional term, integral term, and derivative term) and use these error terms as inputs to the motor control circuit to adjust the motor control. In at least one case, the error terms include displacement error, speed error, and overshoot error. Any combination of these error terms may be used as an input to the motor control circuit.

[0225] In at least one case, one or more parameters are monitored, for example, during the firing stroke and used as inputs into a motor control circuit including a PID controller, for example, to adjust the motor control.

[0226] In at least one instance, PID controller parameters, such as proportional, integral, and / or derivative parameters, are adjusted or fine-tuned based on one or more monitored parameters within the motor system. Such monitored parameters can include, for example, motor response, firing member load, speed, displacement, and / or tissue properties.

[0227] In at least one instance, a PID feedback control system includes a PID controller that includes a proportional element (P), an integral element (I), and a derivative element (D). The outputs of the P element, I element, and D element are summed by a summer that provides a control variable to the process. The output of the process is the process variable. The summer calculates the difference between the desired setpoint and the measured process variable. The PID controller continuously calculates an error value (e.g., the difference between a closing force threshold and a measured closing force) as the difference between the desired setpoint (e.g., a closing force threshold) and the measured process variable (e.g., the speed and direction of a closing tube), and applies a correction based on the proportional, integral, and derivative terms calculated by the proportional element (P), integral element (I), and derivative element (D), respectively. The PID controller attempts to minimize the error e(t) over time by adjusting the control variable (e.g., the speed and direction of a closing tube).

[0228] According to the PID algorithm, the “P” element considers the current value of the error. For example, if the error is large and positive, then the control output will also be large and positive. The error term is, for example, the difference between a reference speed or target speed and an actual output speed. The “I” element considers past values of the error. For example, if the actual speed does not reach the target speed within a certain period of time, then the integral of the error will accumulate over time, and the controller will respond by applying a stronger action. The “D” element considers the likely future trend of the error based on its current rate of change. For example, continuing the above P example, when a large positive control output successfully brings the error closer to zero, it also places the process on a path to a large negative error in the near future. In this case, the derivative becomes negative, and the D module reduces the intensity of the action to prevent the overshoot. More details of the PID control of the surgical instrument system are disclosed in U.S. Patent Application Serial No. 15 / 636,829, now U.S. Patent Application Publication 2021 / 0244407, titled “METHODS FOR CLOSED LOOP VELOCITY CONTROL FOR ROBOTIC SURGICAL INSTRUMENT,” which is incorporated herein by reference in its entirety.

[0229] Fine-tuning the PID controller parameters can provide greater motor control in various situations. For example, the PID controller parameters can be adjusted corresponding to the type and / or thickness of the tissue to be sutured and cut. In at least one case, the PID controller parameters can be adjusted, for example, based on the type of cartridge installed within the end effector, the size of the staples within the installed cartridge, and / or the length of the installed cartridge.

[0230] In at least one case, the expected compression clamping load (the pressure generated due to the tissue clamped within a predetermined tissue gap between the cartridge and the anvil) can indicate the PID adjustment or control parameters. For example, if the expected compression clamping load is exceeded during the clamping phase of the end effector, the PID controller parameters can be adjusted correspondingly to compensate. Similarly, if the expected compression clamping load is not exceeded during the clamping phase of the end effector, the PID controller parameters can be set accordingly, or in at least one case, not adjusted from the preset parameter distribution set prior to clamping the tissue.

[0231] In at least one case, the result of an expected stroke event can trigger one or more adjustments to the PID controller parameters. For example, the occurrence of the stroke, the part of the stroke where an impact is expected (where the firing member may impact the end of the staple cartridge, the initial contact between the firing member and the slider during the start of the stroke, and / or the engagement between the jaw cam surfaces of the tissue gap between the control jaws) can all trigger PID control parameter adjustments. For example, as the firing member contacts the slider at the start of the stroke, the load within the motor system can be detected, and depending on the magnitude of the detected load, the PID controller parameters can be set according to the magnitude of the detected load. In at least one case, for example, a maximum acceptable inertial impact is set or predetermined, and if exceeded, the PID controller parameters are adjusted and / or a safety motor control algorithm is initiated.

[0232] In at least one case, overshoot is monitored throughout the stroke, and the PID controller parameters are adjusted based on the overshoot during the stroke to reduce the likelihood that the firing member travels too far and / or not far enough. For example, the PID controller parameters are adjusted such that the firing member of the motor system does not crash into the staple cartridge and / or the end of the end effector. In at least one case, for example, the PID controller parameters are adjusted such that the firing member of the motor system does not stop prematurely before reaching its expected full firing stroke distance. Such an arrangement can, for example, reduce unnecessary loads on the motor system and / or incomplete staple firing strokes.

[0233] In at least one case, the PID controller parameters are adjusted to place the motor of the motor system in different efficiency bands of the motor curve. Such an arrangement can reduce motor heating and the degradation of performance over time.

[0234] In various situations, for example, adjust or modify PID controller parameters based on any number of variables, such as PID controller gains. In at least one situation, adjust one or more PID controller parameters based on the activation of a magazine lock. In at least one situation, adjust one or more PID controller parameters based on the accuracy of a motor. For example, motor performance can vary over time. A rotational position sensor (such as, for example, an intermeshing gear encoder) can be used to measure the accuracy of the motor. Depending on the measured accuracy, for example, the gain of the PID controller can be modified according to the measured accuracy and, in at least one situation, modified to, for example, compensate for an increase or decrease in accuracy. In at least one situation, modify one or more PID controller parameters based on the position of a cutting edge. In at least one situation, modify one or more PID controller parameters based on the set value of the PID parameters themselves. For example, if the automatic adjustment of PID controller parameters exceeds a threshold, for example, a new set of values can be selected for the PID controller parameters. In at least one situation, modify one or more PID controller parameters based on the end position of a firing stroke. In at least one situation, the end of the firing stroke is predetermined. In at least one situation, the end of the firing stroke varies with each use. For example, the user may not actuate the firing member through the entire firing stroke. The actual end of the firing stroke can be utilized to adjust the gain of the PID controller.

[0235] In at least one situation, adjust one or more PID controller parameters based on one or more magazine characteristics (such as, for example, the type of magazine installed). In at least one situation, use a sensor to determine the color of the magazine and adjust one or more PID controller parameters to a value corresponding to the detected magazine color. For example, a magazine of a first color may require more force to fire its staples than a magazine of a second color. For example, one or more PID controller parameters can be adjusted to compensate for the increased force requirement.

[0236] In at least one situation, for example, adjust one or more PID controller parameters based on motor impedance, the change in Kt (motor torque constant) / Ke (back EMF constant) due to self-heating compared to the nominal Kt / Ke of the motor, and / or the demagnetization of the motor due to long-term use under high-temperature conditions.

[0237] In at least one situation, adjust one or more PID controller parameters based on stress detected within the system. In at least one situation, traces are employed on a printed circuit board or printed circuit board assembly of a surgical instrument system to infer bending stress within the system. For example, the printed circuit board can be positioned within a surgical instrument handle. For example, the PID controller parameters can be adjusted to compensate for the detected bending stress.

[0238] In at least one case, heat accumulation within the system can be detected and one or more PID controller parameters can be adjusted accordingly. For example, the output motor torque may be related to heat accumulation, and when a magnitude and / or threshold rate of heat accumulation that will subsequently result in a certain threshold torque loss is detected, one or more PID controller parameters can be adjusted to, for example, reduce heat accumulation and / or compensate for torque loss.

[0239] In at least one case, the PID controller parameters are adjusted based on the position of the firing member within its firing stroke. For example, the motor control circuit can automatically adjust the PID controller parameters when the firing member has been deployed two-thirds of the entire nail firing stroke. In at least one case, for example, the force increases within the last third of the nail firing stroke, and thus the PID controller parameters can be set to compensate for the expected increase in the required firing force. In at least one case, one or more PID controller parameters are adjusted based on the position where the tissue is longitudinally clamped between the jaws. For example, tissue clamped between the jaws near the distal end may require a greater force for cutting and suturing than tissue clamped between the jaws near the proximal end. One or more PID controller parameters can be adjusted accordingly. In various cases, the system load, distal node system efficiency, and / or torsional drive shaft stiffness can be utilized to adjust the PID controller parameters. In at least one case, one or more strain gauges are used to detect stress within the system.

[0240] In at least one case, for example, one or more PID controller parameters are adjusted based on the number of firings performed by the motor system. For example, an older motor may generate more heat during firing, and thus the PID controller parameters can be adjusted to account for the increased heat risk.

[0241] In various cases, for example, a new value of the PID controller parameters can be estimated through a neural network in order to predict the optimal value of the PID controller parameters for future firings. In at least one case, the motor control circuit uses a schedule to determine when to change the PID controller parameters. For example, after a predetermined number of firings, the PID controller parameters can be automatically adjusted based on reaching the predetermined number of firings. In at least one case, the previous use of a similar motor is recorded and analyzed to determine the PID controller parameters for the local motor system.

[0242] In various cases, for example, the PID controller parameters are tuned to adapt during the use of the motor system to increase motor efficiency and / or improve firing stroke results. See Figure 40, a graph 14030 is shown to describe various setpoint meanings such as for a PID controller. As can be seen in the graph, the rise time, percent overshoot, settling time, and steady state error can all be optimized or improved by adjusting the PID tuning parameters of a PID controller that is configured to control a motor of a surgical instrument motor system. The adjustment can be based on any combination of the methods and systems disclosed herein. For example, in the case of firing member displacement, automatically tuning the PID controller parameters to reduce (e.g., the displaced) percent overshoot can reduce the likelihood of the firing member crashing into the end of the staple cartridge.

[0243] Figure 41 is a logic flow diagram of a process 14040 that can be performed by a control circuit (such as Figure 13 the control circuit 1932 shown in Figure 14 and / or the control circuit shown in ), which uses closed-loop control, for example, here. In at least one case, feedback is generated from one or more system sensors and the input signal is adjusted to optimize motor control. First, a first set of motor control parameters is selected 14041. In at least one case, the motor control parameters include PID controller parameters. In at least one case, the motor control parameters include PWM controller parameters. In at least one case, the motor control parameters include a duty cycle range. In at least one case, the motor control parameters include any combination of the proportional, integral, and derivative tuning parameters of the motor controller. The motor control parameters can include any suitable combination of the control parameters disclosed herein. During operation 14042 of the motor system, one or more parameters of the motor system are monitored 14043. The one or more monitored parameters can include any suitable parameters such as, for example, the position of the firing member, the actual measured speed of the firing member, the actual measured speed of the motor, and / or the type of cartridge installed within the end effector. The monitored parameters can include any combination of the parameters disclosed herein. Based on the monitored parameters, the motor controller parameters are adjusted 14044 to a new set of motor controller parameters. For example, a more stringent or larger range of duty cycles is selected and / or the PID tuning parameter values are adjusted. Any suitable adjustment can be made, such as those disclosed herein.

[0244] Still referring to Figure 41, the motor control circuit is configured to be able to deploy the firing member through the staple firing stroke. In at least one case, the staple firing stroke includes an active stroke portion and an inactive stroke portion, wherein no adjustment to the motor controller parameters is made during the inactive stroke portion, and adjustment can be made during the active stroke portion. In at least one case, the magnitude of the adjustment made to the motor controller parameters is based on the magnitude of the monitored parameter. In at least one case, the magnitude of the adjustment made to the motor controller parameters is based on the rate at which the monitored parameter changes during a portion of the staple firing stroke. In at least one case, when it is detected that the firing member or the motor is decelerating, the new set of motor controller parameters includes a first magnitude. In this case, when it is detected that the firing member or the motor is accelerating, the new set of motor controller parameters includes a second magnitude different from the first magnitude.

[0245] In various cases, for example, the motor control circuit is configured to be able to activate and / or deactivate one or more motor control circuits and / or algorithms, such as those disclosed herein. In at least one case, the motor control circuit is configured to be able to deactivate motor control adjustments during any suitable portion of the drive stroke of the motor system. For example, motor system capacity interrogation and corresponding adjustments may be prohibited from occurring during one or more portions of the stroke of the firing member, but may only be able to occur during one or more other portions of the stroke of the firing member. In at least one case, motor control adjustments may only occur when the firing member positions the staple within the staple deployment zone of the stroke. In at least one case, only certain motor control adjustments corresponding to clamping tissue may occur during tissue clamping, while other certain motor control adjustments corresponding to firing the staple and cutting tissue may occur during the staple firing stroke. In at least one case, the position of the firing member triggers the active and / or inactive phases of the motor control algorithms and circuits, such as those disclosed herein. For example, once the firing member reaches a first position, which can be detected in any suitable manner such as, for example, with a position sensor, a first set of motor control algorithms can be initiated. Similarly, when the firing member reaches a second position, a second set of motor control algorithms can be initiated. Finally, when the firing member reaches a third position, real-time motor control adjustments can be prohibited. In at least one case, portions of the stroke may allow PWM speed control adjustments, while other portions of the stroke may prohibit PWM speed control adjustments.

[0246] In at least one instance, for example, the motor control circuit employs PWM speed control adjustments during clamping of tissue and articulation of the end effector, while PWM speed control adjustments are prohibited during retraction of the firing member, release of the tissue, and / or de-articulation of the end effector to the neutral position. The various motor control circuits and / or algorithms disclosed herein configured to be able to modify the motor speed of the motor system during the drive stroke may be referred to as active speed control. In various instances, active speed control is disabled for one or more reasons. In at least one instance, active speed control may be disabled due to an unforeseen event such as, for example, a detected motor current spike. In at least one instance, the disabling of active speed control may be overridden and reactivated. In at least one instance, for example, the user may manually disable and / or enable active speed control. In at least one instance, disabling active speed control is configured to be able to directly connect the power source to the motor, thereby removing any intelligent control of the motor. In at least one instance, the PWM speed control may be deactivated, and in such a case, the duty cycle of the motor is set to a fixed value such as, for example, 100%, and no PWM motor controller adjustments are made. In at least one instance, the motor control profile is reset from stroke to stroke, patient to patient, and / or cassette to cassette. In at least one instance, the motor control profile is not reset.

[0247] In at least one instance, for example, the motor control circuits and algorithms disclosed herein are configured to be able to maintain a constant speed of the firing member as it traverses tissue rather than constantly varying the speed of the firing member.

[0248] In various instances, for example, the staple cartridge and / or staple firing stroke is defined as multiple segments, where certain motor control adjustments are restricted to a predetermined adjustment range. For example, such control circuits may also be used during the closing stroke of the drive shaft. Each segment corresponds to certain motor controller adjustments. For example, during the first third of the staple firing stroke, the control circuit may only be able to make a first range of adjustments to one or more motor controller parameters such as, for example, PID tuning parameters. During the second third of the staple firing stroke, the control circuit may only be able to make a second range of adjustments to one or more motor controller parameters. Finally, during the third third of the staple firing stroke, the control circuit may only be able to make a third range of adjustments to one or more motor controller parameters.

[0249] In at least one case, the adjustment range that can be made during the first third of the nail driving stroke can include a greater range compared to the adjustment ranges of the second third and / or the third third. This can reduce the likelihood of making large motor control adjustments during the final stage of the nail driving stroke, where the user may not want the firing member to increase its speed towards the end of the nail driving stroke for fear of risking driving the firing member into the end of the nail magazine, which can cause the firing member to jam or become trapped, for example. In at least one case, there are no restrictions on motor controller adjustments during the first third of the nail driving stroke. In at least one case, no motor controller adjustments can be made during the last third of the nail driving stroke.

[0250] For example, the segmented sections of the nail driving stroke can be divided into any desired parts. For example, the nail driving stroke can be segmented into, for example, quarters, fifths, hundredths. In at least one case, the nail driving stroke is divided into two regions. In various cases, the lengths of the segments are different. In at least one case, the segments are divided into a start segment, a plurality of intermediate segments, and an end segment.

[0251] In various cases, dividing the nail driving stroke into segments (where motor control adjustments are limited, constrained, or specifically controlled within each segment) can control overshoot errors during motor operation. For example, the load or the driving force can be monitored during each segment and used to set motor controller parameters, such as, for example, PID tuning values specific to each segment.

[0252] Figure 42FIG. 14050 is a graph showing the firing stroke of a motor system. The control circuit divides the firing stroke or the cartridge into several segments: the first third, the second third, and the third third. The control circuit increases the target speed 14051 of the motor to a safe speed to start firing. Then, the control circuit increases the target speed 14051 of the motor by increasing the duty cycle to a relatively high duty cycle during the first third of the cartridge. As can be seen in FIG. 14050, the overshoot error of the actual speed 14052 increases during the rapid acceleration of the firing member. The actual speed 14052 of the firing member stabilizes towards the end of the first third of the cartridge. Then, the target speed 14051 drops to another safe target speed 14051. As also can be seen in FIG. 14050, the load 14053 during the first third of the cartridge is relatively low compared to the other segments of the cartridge. As the load increases 14054 during the second third of the cartridge, the control circuit sets the target speed 14051 and the actual speed 14052 of the firing member increases at a rate lower than the rate of speed increase during the first third of the cartridge. This also results in less overshoot error. Finally, in the case where the load 14055 increases again during the third third of the cartridge, the target speed 14051 is set and the firing member accelerates slowly to reduce the overshoot within the third third of the cartridge. As the load increases throughout the firing stroke, the duty cycle of the motor decreases for each segment to reduce overshoot. High overshoot may damage tissue or damage the firing system itself. Reducing overshoot during higher load conditions can reduce the likelihood of damaging tissue and / or the firing system. In at least one case, the load 14053, 14054, and 14055 is measured while the motor is running at a safe speed before increasing the target speed 14052 of the firing member for each segment of the cartridge. In this case, the speed of the firing member is adjusted according to the magnitude of the measured load, where a higher load results in a lower set speed, while a lower load results in an increased set speed. In at least one case, the speed can increase significantly during low load conditions because the risk to tissue and / or the firing system can be reduced at high speeds with a low detected load. The increased overshoot error during higher load conditions can result in an additional unexpected speed increase from the target speed, where no tissue damage or system damage is expected at the target speed, but tissue damage or system damage will occur if the increased speed is reached during overshoot of the target speed.

[0253] In various situations, the PID controller parameters are automatically adjusted to reduce overshoot under higher load conditions. Under lower load conditions, the PID controller parameters can be automatically adjusted to optimize speed, where overshoot is not a problem. In at least one situation, the threshold of the proportional limit value of the PID controller is reduced under higher load conditions to reduce overshoot. In at least one situation, the thresholds of the integral value and the derivative value of the PID controller are reduced to reduce overshoot. In various situations, the rate of change of the speed of the firing member is monitored to determine motor control adjustments for the remainder of each segment, such as, for example, PID tuning value adjustments.

[0254] In at least one situation, overshoot and / or irregular motor response may be acceptable and / or expected during certain portions of the firing stroke. During such portions of the firing stroke, using the position of the firing member to determine when the firing member is in such portions of the firing stroke, the motor control circuit can specifically tune the PID controller values accordingly. In at least one situation, the predicted amount of overshoot is acceptable during a portion of the firing stroke. Accordingly, the PID controller values are adjusted. In at least one situation, the PID controller values are not adjusted at all during such portions of the firing stroke. In various situations, the firing stroke includes predicting the position of the firing force spike, where the firing force increases at the spike position whenever the firing member passes through the spike position. Such positions can include the position where the I-beam contacts and passes through a metal irregularity in the magazine channel, and the metal irregularity is the result of the manufacturing process of the magazine channel. In this case, the motor control circuit is configured to be able not to adjust the PID controller values when the firing member passes through the spike position. The position of the firing member can be used to determine when the firing member will pass through the spike position to prevent the motor control circuit from adjusting the motor controller parameters when the firing member passes through the spike position / due to the spike in the firing force. In at least one situation, the motor control circuit adjusts the PID controller values at the spike position; however, the amount of adjustment is lower than the case where the same force spike is detected during other portions of the nailing stroke.

[0255] In various situations, the rate of speed increase or decrease (acceleration / deceleration) achieved by the motor control circuit is adjusted based on, for example, the level of overshoot considerations and / or undershoot considerations related to predictable loads at certain positions. Figure 43Graph 14060 shows the firing stroke of the motor system. The target or set speed 14061, the actual measured speed 14062, and the firing loads 14063, 14064, and 14065 are shown. During stage (1), the speed of the motor increases at the start A_1 of the firing stroke. During stage (1), the overshoot problem is low, and thus the motor control circuit sets the motor control parameters accordingly (e.g., to allow overshoot). The overshoot problem is low because no tissue is being cut or sutured during this stage of the firing stroke. Instead, the firing member moves from the non-firing position A_1 to the locked position, where the firing member is locked and cannot continue or fail to lock. During this stage, the overshoot problem is low. Before reaching the locked position, the speed 14061 decreases. During this decrease, undershoot is not a problem, and thus the motor control parameters are set / adjustable accordingly. The speed 14061 may decrease just before the firing member reaches the locked position to reduce the effective speed before the firing member locks or fails to lock. The increased speed before the speed decrease at A_2 increases the operating efficiency of the motor before the firing member reaches the locked position. The load 14063 during stage 1 may be known and / or predicted with acceptable accuracy such that there may be no unpredictable load increase / decrease during this stage. Since the load is predicted within this stage, the motor controller parameters can be set accordingly.

[0256] After the firing member fails to lock and moves past the locked position, stage 2 begins. At B_1, the speed 14061 increases because the load 14064 is unknown. The load 14064 is unknown because at any point during stage 2, the firing member (or cutting member) may strike tissue. Also, because the load 14064 is unknown, overshoot is a greater problem than in the case of stage 1. Overshoot during tissue impact during this stage can cause tissue damage by applying an inertial force greater than the predicted inertial force. This higher-than-predicted inertial force is because the initial spike (overshoot) of the input speed experienced exceeds the set target speed. Since overshoot is a greater problem, the motor control parameters can be set accordingly to reduce the rate of increase of the speed of the firing member. As can be seen in graph 14060, the overshoot of the actual speed 14062 is low because the motor control parameters are set accordingly. In stage 3, the load 14065 is unknown, and undershoot is considered at B_2 where the relatively low speed 14062 decreases. Undershoot may not be a problem in several scenarios because slowing the firing member from a higher speed to below the target speed may not pose a risk of damaging tissue.

[0257] In various cases, the motor control circuit can use dynamic braking to reduce overshoot. In at least one case, the actual speed is monitored and compared with the target speed, and as the actual speed approaches the target speed, the motor can be dynamically slowed down or braked to reduce and / or eliminate overshoot and / or undershoot. In at least one case, dynamic braking is used in combination with acceleration limits to control overshoot. In at least one case, the inertia of the motor system is monitored during the strike stroke and used to determine acceleration limit adjustments.

[0258] In various cases, an importance metric is utilized in the motor control circuit. For example, the importance metric is a value assigned to a predetermined section of the strike stroke. This value indicates, for example, the importance or lack of importance of reducing overshoot and / or undershoot during the identified strike stroke section. See Figure 43 , for example, an importance metric value of "1" can be assigned to position B_1 as the most important position for reducing overshoot, and importance metric values of "2" can be assigned to positions A_1, A_2, and B_2, indicating a lower importance of reducing overshoot and / or undershoot.

[0259] In various cases, for example, the rate of change of speed (via PWM duty cycle, PWM frequency, PWM amplitude (voltage)) can be monitored relative to a target threshold to adjust motor control parameters to reduce and / or eliminate overshoot. In at least one case, the motor control circuit is configured to be able to monitor the magnitude of the PID deviation from the instantaneous target over time at a specific frequency and monitor the rate of change of the PID deviation during that time period to determine whether the motor system is falling further behind with each subsequent target or whether the motor system is accelerating towards the target with each subsequent target. This determination can be used in combination with how far the actual value is from the target at each target to inhibit acceleration / deceleration and thus prevent overshoot / undershoot. In at least one case, for example, the rate of change of speed is monitored at the beginning and / or at the end of each stage, cycle, or strike stroke section.

[0260] Figure 44 is a depiction that can be made by a control circuit (such as Figure 13 the control circuit 1932 shown in Figure 14Logic flow diagram of process 14070 performed by the control circuit (shown in [reference]) that is configured, for example, to control a motor of a motor system. The motor control circuit is configured to monitor 14071 the position of a firing member. The position of the firing member can be monitored in any suitable manner, such as, for example, by a position sensor, a displacement sensor, and / or an encoder configured to measure motor rotation. The motor control circuit is further configured to determine 14072 the stage of the firing stroke in which the firing member is located based on the monitored position of the firing member. For example, based on the monitored position of the firing member, the motor control circuit can determine that the firing member is within the first third of the magazine or, for example, within the first of three segments of the firing stroke. The motor control circuit is further configured to determine 14073 a corresponding importance metric for the determined stage, as it relates to the degree of overshoot problem occurring within the determined stage. In at least one case, the importance metric includes a scale comprising low importance, medium importance, and high importance. Low importance indicates that the occurrence of overshoot is of little concern. High importance indicates that the occurrence of overshoot is a significant problem. High importance can be associated with stages of the firing stroke where the load on the firing member is higher. In at least one case, the importance metric is determined based on the position of the firing member. In at least one case, the load on the firing member is monitored and used to determine the importance metric. For example, a higher load on the firing member may be associated with a higher degree of overshoot problem. The motor control circuit is further configured to adjust 14074 one or more motor control parameters according to the determined importance metric to control the rate at which the speed of the firing member changes during the determined stage. The one or more parameters can include any suitable parameters, such as, for example, motor controller parameters, PID controller tuning parameters, and / or PWM duty cycle ranges.

[0261] In various cases, motor control parameters, circuits, and / or algorithms (such as those disclosed herein) are adjusted in an effort to limit the loads experienced within the end effector. For example, such loads may be caused by thick and / or tough tissue. The motor can experience loads at various stages of using the surgical instrument. For example, as the firing member is advanced through the staple firing stroke, the motor can experience a load through the firing member, and, for example, during tissue clamping, the motor can experience a load through the closure member. The load level can be detected in any suitable manner, such as, for example, by monitoring the motor current of a motor configured to drive the firing member and / or by a force sensor such as a strain gauge positioned on the firing member. In at least one case, the speed of the motor of the motor system is reduced to reduce the load experienced by the firing member.

[0262] In at least one instance, the motor control circuit is configured to be able to modulate both the torque (force) and speed (voltage) of the motor simultaneously in an effort to reduce the load experienced by the drivetrain. In at least one instance, the speed of the motor is reduced to reduce the load experienced within the end effector. In at least one instance, a controlled pause or wait period is utilized to reduce the load experienced within the end effector.

[0263] Figure 45 is a logic flow diagram depicting a process 15000 that may be performed by a control circuit (such as Figure 13 the control circuit 1932 shown in Figure 14 and / or the control circuit shown in

[0264] ), and which may be used, for example, in conjunction with a surgical instrument system (such as those disclosed herein). The control circuit is configured to be able to control a motor of a motor system within the surgical instrument system. The control circuit is configured to be able to receive one or more inputs and generate an output signal to the motor corresponding to the one or more inputs. The control circuit is configured to be able to monitor one or more electrical and / or mechanical parameters of the motor system, such as, for example, the rotational output speed of the motor, the linear output speed of the firing member, the current draw of the motor, and / or the load experienced by the motor system. In at least one instance, the control circuit is configured to be able to convert one or more analog outputs (such as motor speed, current draw, firing member speed, etc.) into digital signals. In at least one instance, a digital control signal is configured to be able to be converted into an analog input signal for the motor. In at least one instance, one or more analog output signals are configured to be able to be converted into digital signals that may be fed back into the control circuit and used as inputs to the control circuit.

[0265] In the event that the load threshold is triggered, for example, it can be determined that the firing member is encountering a hard or thick slice of tissue. In at least one case, the control circuit adjusts one or more motor control parameters to overcome the difficulties posed by hard tissue. In at least one case, an oscillating signal is transmitted to the motor such that the motor repeatedly impacts the tissue over a period of time in an effort to penetrate the thick tissue. In at least one case, a PWM signal is used to provide motor oscillation. In at least one case, the motor oscillation involves a series of rapid energy bursts. In at least one case, the control circuit is configured to be able to move the firing member in the proximal direction prior to each energy burst in an effort to increase the moment of inertia when impacting the thick tissue. In at least one case, a combination of pulse width modulation other than pulse amplitude modulation is utilized.

[0266] The width (time) of each pulse can be adjusted based on one or more monitored parameters such as, for example, the magnitude of the load experienced by the firing member. Similarly, the amplitude (voltage) of each pulse can be adjusted based on one or more monitored parameters such as, for example, the magnitude of the load experienced by the firing member. In various cases, the width of each pulse and / or the amplitude of each pulse varies as the firing member traverses the thick tissue. In at least one case, the firing member oscillates in the manner described above for a period of time, pauses, and then oscillates again. In at least one case, the duration of the oscillating motor operation can depend on one or more monitored parameters. For example, when the load experienced by the firing member drops below a predetermined load threshold, for example, normal firing member operation can resume. In at least one case, the control circuit employs a delay in order to ensure that the firing member clears the slice of thick tissue, thereby allowing the oscillating signal to power the firing member at a predetermined distance after the moment when the load on the firing member drops below the predetermined threshold.

[0267] In at least one case, a delta-sigma modulation based bitstream controller is utilized in the control circuit to drive the motor. Such a controller can utilize an analog output and generate a digital control signal. An example of a delta-sigma modulator 15010 can be seen in Figure 46 In. The delta-sigma modulator 15010 is a second-order delta-sigma modulator. As Figure 46 shown, in addition to two integrators 15012, two feedback loops 15011 are also used. A 1-bit DAC 15013 is also used. Finally, a digital filter 15014 is employed to form a high-resolution digital output.

[0268] As discussed herein, the control circuit can also use pulse amplitude modulation to control the motor. Figure 47Depicts a graph 15020 depicting a first signal 15021 and a pulse amplitude modulated signal 15022 representing the first signal 15021. Pulse amplitude modulation can provide a varying voltage amplitude for motor control. In at least one case, a combination of variable output forces can be achieved by moving up and / or down on the torque-power curve of the motor. In at least one case, the duty cycle is also used in combination with pulse amplitude modulation to adjust the voltage and / or power applied to the motor to control the motor speed.

[0269] In various cases, pulse width frequency modulation is used to control the speed of a motor in a surgical instrument system. In at least one case, the control circuit is configured to be able to monitor the current passing through the motor. As a supplement or alternative to changing the duty cycle of the PWM signal, the control circuit can be configured to be able to modulate the frequency of the pulses. For example, the modulation of the pulse frequency can be adjusted based on one or more monitored parameters of the drive stroke. In at least one case, the control circuit is configured to be able to adjust the frequency of the pulses to a first frequency when a first parameter threshold is detected and to a second frequency when a second parameter threshold is detected. The first frequency is different from the second frequency, and the first parameter threshold is different from the second parameter threshold. In at least one case, a faster frequency can reduce the current draw through the motor. Figure 48 Depicts two graphs 15030, 15040 of PWM signals 15031, 15041 versus the current draw (I) through the motor at two different frequencies. As seen in Figure 48 it, for the same 50% duty cycle, the current draw 15032 is greater than the current draw 15042. In at least one case, pulse frequency modulation is advantageous in a brushless DC motor that uses multiple electromagnets in a frequency cascade. The speed of the brushless DC motor can be controlled with little effect on the motor torque output.

[0270] Figure 49 Is a graph 15050 of various signals 15051, 15052, and 15053 depicting the duty cycle of the signals versus the current draw through the motor at different frequencies F1 (frequency of signal 15051), F2 (frequency of signal 15052), and F3 (frequency of signal 15053). In at least one case, F1 is greater than F2, and F2 is greater than F3. In at least one case, a higher frequency can reduce the current draw through the motor.

[0271] In various cases, a control circuit configured to control a motor of a motor system is configured to use pulse amplitude modulation and / or pulse width frequency modulation in conjunction with a wait or pause period. In at least one case, the control circuit is configured to monitor the current through the motor and adjust the pulse width frequency and / or pulse amplitude based on the monitored current. In at least one case, the adjustment occurs after the wait or pause period. In at least one case, the wait or pause period is predetermined. In at least one case, the wait period is variable. In at least one case, the wait period depends on the magnitude of the monitored current. For example, the control circuit may set the wait period to a first period after detecting a first current and set the wait period to a second period greater than the first period after detecting a second current greater than the first current. In at least one case, when the current through the motor exceeds a predetermined current level, such a controlled wait or pause time can reduce the load experienced by the firing member during the firing stroke. Setting the magnitude of the period corresponding to the detected current level through the motor can allow for situation-specific wait times, where, for example, a longer wait period may not be required at lower current thresholds.

[0272] Figure 50 is a logic flow diagram of a process 15060 that may be performed by a control circuit (such as Figure 13 control circuit 1932 shown in Figure 14 and / or the control circuit shown in) and is configured, for example, to control a motor of a motor system of a surgical instrument system. The control circuit is configured to initiate 15061 a drive stroke of the motor system. For example, such a drive stroke may include a staple firing stroke of a firing member. During the drive stroke, the control circuit is configured to monitor 15062 the current draw of the motor. Any suitable monitoring method may be used, such as, for example, using a current transducer. The control circuit is configured to determine 15063 when the monitored current exceeds a predetermined threshold. The predetermined threshold may indicate an overcurrent situation, where, for example, the firing member has encountered thick tissue, thereby increasing the load on the firing member and thus increasing the current draw of the motor. Upon determining that the predetermined threshold has been exceeded, the control circuit is configured to initiate 15064 a sequence of oscillatory shock signals for the motor.

[0273] In at least one case, the oscillatory shock signal sequence includes digital motor control signals. In at least one case, the pulse width, pulse amplitude, and / or pulse frequency are preselected. In at least one case, the pulse width, pulse amplitude, and / or pulse frequency are selected when it is determined that a predetermined current threshold has been exceeded. In at least one case, for example, the pulse width, pulse amplitude, and / or pulse frequency are selected based on one or more monitored parameters of the motor system, such as the magnitude when the current exceeds the predetermined current threshold. In at least one case, each pulse delivered to the motor can correspond to a distal shock movement of the firing member. In various cases, for example, a reverse movement or pulse can be applied to each distal pulse movement to allow the firing member to acquire a certain distance amount to gain momentum, thereby striving to penetrate a thick slice of tissue. In at least one case, the oscillatory shock signal sequence further includes a pause period configured to allow tissue relaxation. In at least one case, a predetermined number of distal pulse movements of the firing member occur before the pause period. In at least one case, a number of pause periods can be used until the thick tissue is penetrated by the firing member.

[0274] Aspects of the subject matter described herein are set forth in the following embodiments, which may or may not be claimed.

[0275] Embodiment 1 - A surgical instrument system, the surgical instrument system including a motor system, the motor system including a motor and a drive train that can be coupled to the motor and is configured to be able to actuate a firing member through a staple firing stroke. The surgical instrument system further includes a control circuit coupled to the motor, wherein the control circuit includes a motor controller configured to be able to control the motor, and wherein during the staple firing stroke, the control circuit is configured to be able to: operate the motor within a certain duty cycle range; monitor parameters of the motor system; adjust the duty cycle range based on the monitored parameters of the motor system during the staple firing stroke; and operate the motor within the adjusted duty cycle range.

[0276] Embodiment 2 - The surgical instrument system according to Embodiment 1, wherein the parameter of the motor system includes a firing load.

[0277] Embodiment 3 - The surgical instrument system according to Embodiment 1 or 2, wherein the parameter of the motor system includes the position of the firing member.

[0278] Embodiment 4 - The surgical instrument system according to any one of Embodiments 1 to 3, wherein the parameter of the motor system includes the actual measured speed of the firing member.

[0279] Example 5 - The surgical instrument system according to any one of Examples 1 to 4, wherein the parameter of the motor system includes the actually measured speed of the motor.

[0280] Example 6 - The surgical instrument system according to any one of Examples 1 to 5, wherein when it is detected that the motor is decelerating, the adjusted duty cycle range includes a first range, and wherein when it is detected that the motor is accelerating, the adjusted duty cycle range includes a second range different from the first range.

[0281] Example 7 - The surgical instrument system according to any one of Examples 1 to 6, wherein the parameter of the motor system includes motor current.

[0282] Example 8 - The surgical instrument system according to any one of Examples 1 to 7, wherein the firing stroke includes an active stroke portion and an inactive stroke portion, and wherein adjustment of the duty cycle range is restricted during the inactive stroke portion.

[0283] Example 9 - The surgical instrument system according to any one of Examples 1 to 8, wherein the control circuit is further configured to be able to adjust any combination of the proportional, integral, and derivative tuning parameters of the motor controller based on the monitored parameter during the firing stroke.

[0284] Example 10 - The surgical instrument system according to any one of Examples 1 to 9, wherein the magnitude of the adjustment made to the duty cycle range is based on the magnitude of the monitored parameter.

[0285] Example 11 - The surgical instrument system according to any one of Examples 1 to 10, wherein the magnitude of the adjustment made to the first set of parameters is based on the rate at which the monitored parameter changes during a portion of the firing stroke.

[0286] Example 12 - A surgical instrument system, the surgical instrument system including a motor system, the motor system including a motor and a drive train that can be coupled to the motor and is configured to be able to actuate a firing member through a firing stroke. The surgical instrument system further includes a control circuit coupled to the motor, wherein the control circuit includes a motor controller configured to be able to control the motor, and wherein during the firing stroke, the control circuit is configured to be able to: actuate the firing member through the firing stroke; monitor a parameter of the motor system during the firing stroke; identify when the firing member is within an active adjustment portion of the firing stroke; and automatically adjust a tuning parameter of the motor controller at a certain frequency based on the monitored parameter of the motor system during the active adjustment portion of the firing stroke.

[0287] Example 13 - The surgical instrument system according to Example 12, wherein the parameter of the motor system includes the load applied to the firing member.

[0288] Example 14 - The surgical instrument system according to Example 12 or 13, wherein the parameter of the motor system includes the position of the firing member.

[0289] Example 15 - The surgical instrument system according to any one of Examples 12 to 14, wherein the parameter of the motor system includes the actually measured speed of the firing member.

[0290] Example 16 - The surgical instrument system according to any one of Examples 12 to 15, wherein the parameter of the motor system includes the actually measured speed of the motor.

[0291] Example 17 - The surgical instrument system according to any one of Examples 12 to 16, wherein when it is detected that the motor is decelerating and accelerating, the tuning parameter is adjusted in different ways.

[0292] Example 18 - The surgical instrument system according to any one of Examples 12 to 17, wherein the tuning parameter includes any combination of the proportional, integral, and derivative tuning parameters of the motor controller.

[0293] Example 19 - The surgical instrument system according to any one of Examples 12 to 18, wherein the magnitude of the adjustment made to the tuning parameter is based on the rate at which the monitored parameter changes during a portion of the staple firing stroke.

[0294] Example 20 - A surgical instrument system, the surgical instrument system including a motor system, the motor system including a motor and a drive train that can be coupled to the motor and is configured to be able to actuate a firing member through a staple firing stroke. The surgical instrument system further includes a control circuit coupled to the motor, wherein the control circuit includes a motor controller configured to be able to control the motor, and wherein during the firing stroke, the control circuit is configured to be able to: monitor the position of the firing member; determine, based on the monitored position of the firing member, the stage of the firing stroke in which the firing member is positioned; and adjust the motor control parameter according to the determined stage of the firing stroke to control the rate at which the speed of the firing member changes during the determined stage of the firing stroke, wherein the motor control parameter is configured to be able to be adjusted in different ways for different stages of the firing stroke.

[0295] Many of the surgical instrument systems described herein are actuated by electric motors; 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 some cases, the motor disclosed herein may include a portion or portions of a robotic control system. In addition, 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 number 13 / 118,241 (now U.S. Patent No. 9,072,535), entitled "SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENTARRANGEMENTS," discloses several examples of robotic surgical instrument systems in more detail and is incorporated herein by reference in its entirety.

[0296] The surgical instrument systems described herein have been described in conjunction with the deployment and deformation of staples; however, the embodiments described herein are not limited thereto. For example, various embodiments are contemplated that deploy fasteners other than staples, such as clamps or tacks. In addition, various embodiments are contemplated that utilize any suitable device for sealing tissue. For example, an end effector according to various embodiments may include an electrode configured to heat and seal tissue. Additionally, for example, an end effector according to certain embodiments may apply vibration energy to seal tissue.

[0297] Although multiple forms have been illustrated and described, it is not the intention of the applicant to restrict or limit the scope of the appended claims to such details. Without departing from the scope of the present disclosure, many modifications, variations, changes, substitutions, combinations and equivalents to these forms can be realized, and those skilled in the art will think of many modifications, variations, changes, substitutions, combinations and equivalents to these forms. In addition, alternatively, the structure of each element associated with the described form can be described as a device for providing the function performed by the element. In addition, in the case of disclosing materials for certain parts, other materials can also be used. Therefore, it should be understood that the above-mentioned specific embodiments and the appended claims are intended to cover all such modifications, combinations and variations within the scope of the forms disclosed by the present invention. The appended claims are intended to cover all such modifications, variations, changes, substitutions, modifications and equivalents.

[0298] The above specific embodiments have illustrated various forms of the apparatus and / or method by using 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 virtually any combination thereof. Those skilled in the art will recognize that some aspects of the forms disclosed herein can be equivalently implemented in an integrated circuit, 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 virtually any combination thereof, and 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 the illustrative forms of the subject matter described herein are applicable regardless of the specific type of signal-bearing medium used to actually effect the distribution.

[0299] 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 when transmitting 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 include 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).

[0300] 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, a processing unit, a processor, a microcontroller, a microcontroller unit, a controller, a digital signal processor (DSP), a programmable logic device (PLD), a programmable logic array (PLA), a field programmable gate array (FPGA)), state machine circuitry, firmware that stores instructions executed by the programmable circuitry, and any combination thereof. The control circuit can be implemented collectively or individually as circuitry 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 that forms a general purpose computing device configured by a computer program (e.g., a general purpose computer configured by a computer program that at least partially implements the methods and / or apparatuses described herein, or a microprocessor configured by a computer program that at least partially implements the methods and / or apparatuses described herein), an electronic circuit that forms a memory device (e.g., forms a random access memory), and / or an electronic circuit that forms a communication device (e.g., 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.

[0301] As used in one or more aspects of the present disclosure, a microcontroller generally can include a memory and a microprocessor ("processor") operatively coupled to the memory. The processor can control a motor driver circuit that is generally used to control, for example, the position and rate of a motor. In some cases, the processor can signal the motor driver to, for example, stop and / or disable the motor. In some cases, the microcontroller can be, for example, the LM4F230H5QR available from Texas Instruments. In at least one example, the Texas Instruments LM4F230H5QR is a chip on which an ARM Cortex-M4F processor core includes up to 256KB of single-cycle flash memory or other non-volatile memory at up to 40MHz, a prefetch buffer for improved performance above 40MHz, 32KB of single-cycle serial random access memory (SRAM), loaded with The built-in read-only memory (ROM), 2KB electrically erasable programmable read-only memory (EEPROM), one or more pulse width modulation (PWM) modules, one or more quadrature encoder input (QEI) simulations, one or more 12-bit analog-to-digital converters (ADCs) with 12 analog input channels, and other characteristic structures readily available in the product data sheet of the software.

[0302] It should be understood that as used herein, the term processor includes any suitable microprocessor or another basic computing device that combines the functions of a central processing unit (CPU) of a computer on one integrated circuit or at most a few integrated circuits. A processor is a multi-purpose programmable device that receives digital data as input, processes the input according to instructions stored in its memory, and then provides the result 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.

[0303] In at least one case, the processor can 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 can be adopted without limitation.

[0304] As used in any aspect herein, the term "logic" can refer to an application program, software, firmware, and / or circuitry configured to be capable of performing any of the foregoing operations. Software can be embodied as a software package, code, instructions, instruction sets, and / or data recorded on a non-transitory computer-readable storage medium. Firmware can be embodied as code, instructions, or instruction sets and / or data hard-coded (e.g., non-volatile) in a memory device.

[0305] As used in any aspect herein, 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.

[0306] As used in any aspect herein, an "algorithm" refers to an ordered sequence of steps that results in a desired outcome, where a "step" refers to the manipulation of physical quantities and / or logical states, which may (but need not) be in the form of electrical or magnetic signals that can be stored, transferred, combined, compared, and otherwise manipulated. Commonly used to refer to these signals are terms such as 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.

[0307] Various instruments, tools, hubs, devices, and / or systems in accordance with the present disclosure may be capable of communicating with each other using a selected packet-switching network communication protocol. An exemplary communication protocol may include an Ethernet communication protocol that may be capable of allowing communication using Transmission Control Protocol / Internet Protocol (TCP / IP). The Ethernet protocol may conform to or be compatible with the Ethernet standard named “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 an 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 a 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 an Asynchronous Transfer Mode (ATM) communication protocol. The ATM communication protocol may conform to or be compatible with the ATM standard named “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 equally contemplated herein.

[0308] As described herein, one or more motor assemblies employ one or more electric motors. In various forms, the electric motor may be, for example, a DC brushed drive motor. 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 electric motor may be powered by a power source that, in one form, may include a removable power pack. The batteries may each include, for example, lithium ion (“LI”) or another suitable battery. The electric motor may include, for example, a rotatable shaft operably engaged with a gear reducer assembly. In certain instances, the voltage polarity provided by the power source may operate the electric motor in a clockwise direction, where the voltage polarity applied to the electric motor by the battery may be reversed to operate the electric motor in a counterclockwise direction. In various aspects, the microcontroller controls the electric motor via a pulse width modulation control signal through a motor driver. The motor driver may be configured to be able to adjust the speed of the electric motor in a clockwise or counterclockwise direction. The motor driver is also configured to be able to switch between multiple operating modes, the multiple operating modes including 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 driving the motor are shorted, and the generated back EMF cancels the rotation of the electric motor, allowing for faster stopping and greater position accuracy.

[0309] 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 including one or more transceivers. The transceivers can include, but are not limited to, cellular modems, wireless mesh network transceivers, transceivers, low power wide area (LPWA) transceivers, and / or near field communication transceivers (NFC). The device can include mobile phones, sensor systems (e.g., environmental, location, motion, etc.) and / or sensor networks (wired and / or wireless), computing systems (e.g., servers, workstation computers, desktop computers, laptop computers, tablet computers (e.g., etc.), ultra-portable computers, ultra-mobile computers, netbook computers, and / or small notebook computers, etc.) or can be configured to be capable of communicating with these devices. In at least one aspect of the present disclosure, one of the devices can be a coordinator node.

[0310] The transceiver can be configured to be capable of receiving serial transmission data from a processor via a corresponding universal asynchronous receiver / transmitter (UART) to modulate the serial transmission data onto an RF carrier to generate a transmission RF signal and transmit the transmission RF signal via a corresponding antenna. The transceiver can be further configured to be capable of receiving a received RF signal (the received RF signal includes an RF carrier modulated with serial received data) via a corresponding antenna, demodulating the received RF signal to extract the serial received data, and providing 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 transmission 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 for IEEE 802.11a / b / g / n and / or for IEEE 802.15.4 for wireless mesh networks using Zigbee routing.

[0311] Unless otherwise expressly specified in the above disclosure, it can be understood that in the above 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.

[0312] One or more components may be referred to herein as “configured to be able to”, “configurable to be able 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 be able to” generally can encompass components in an active state and / or components in a non-active state and / or components in a standby state.

[0313] 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, the surgical instrument is used in many orientations and positions, and these terms are not limiting and / or absolute.

[0314] Those skilled in the art will recognize that, generally speaking, the terms used herein, and particularly 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 introductions to claim recitations is intended, such intent will be expressly recited in the claims, and in the absence of such recitation, no such intent exists. For example, for purposes of illustration, 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” generally should be interpreted to mean “at least one” or “one or more”); this also applies to the use of the definite article to introduce claim recitations.

[0315] In addition, even if a specific number recited in a claim is explicitly recited, those skilled in the art should recognize that such a recitation should generally be interpreted to mean 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). Further, in those cases where a convention such as "at least one of A, B, and C, etc." is used, generally, such a 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 such as "at least one of A, B, or C, etc." is used, generally, such a 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".

[0316] Regarding 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 listed 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 the context otherwise provides, examples of such alternative orderings can include overlapping, interleaving, interrupting, reordering, incrementing, preparatory, supplementary, simultaneous, reverse, or other altered orderings. Further, unless the context otherwise provides, terms such as "responsive to", "associated with", or other past-tense adjectives generally are not intended to exclude such variations.

[0317] It is worth mentioning that any reference to "an aspect", "one aspect", "an example", "one example" means that the specific feature, structure, or characteristic described in connection with the 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 positions throughout the specification do not necessarily all refer to the same aspect. Additionally, the specific feature, structure, or characteristic can be combined in any suitable manner in one or more aspects.

[0318] 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.

[0319] In this specification, unless otherwise specified, all numerical parameters should be understood in all cases to be prefaced by the term "about" or modified by the term "about", where the numerical parameters have the characteristic of the inherent variability of the underlying measurement technique for determining the numerical value of the parameter. 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 the customary rounding method.

[0320] Any numerical range listed herein includes all sub-ranges subsumed within the listed range. For example, the range "1 to 10" includes all sub-ranges between the listed minimum value 1 and the listed maximum value 10 (including 1 and 10), that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 10. In addition, all ranges listed herein include the endpoints of the listed range. For example, the range "1 to 10" includes the endpoints 1 and 10. Any upper limit value listed in this specification is intended to include all smaller limit values subsumed therein, and any lower limit value listed in this specification is intended to include all larger limit values subsumed therein. Accordingly, the applicant reserves the right to amend this specification (including the claims) to expressly list any sub-ranges subsumed within the expressly listed range. All such ranges are inherently described in this specification.

[0321] Any patent application, patent, non-patent publication, or other publicly available 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 purported to be incorporated herein by reference but conflicts with the existing definitions, statements, or other publicly available material listed herein will be incorporated only to the extent that there is no conflict between the incorporated material and the existing publicly available material.

[0322] Broadly speaking, many 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 above-described specific embodiments have been provided. These specific embodiments are not intended to be exhaustive or limiting to the precise forms disclosed in the present invention. Modifications or variations to the present 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 those of ordinary skill in the art can utilize the various forms and various modifications suitable for the particular uses contemplated. The claims submitted herewith are intended to define the full scope.

Claims

1. A surgical instrument system, the surgical instrument system comprising: A motor system, the motor system comprising: A motor; and A drive train that is couplable to the motor and is configured to be able to actuate a firing member through a staple firing stroke; and A control circuit coupled to the motor, wherein the control circuit includes a motor controller configured to be able to control the motor, and wherein, during the staple firing stroke, the control circuit is configured to be able to: Operate the motor within a certain duty cycle range; Monitor parameters of the motor system; Adjust the duty cycle range based on the monitored parameters of the motor system during the staple firing stroke; and Operate the motor within the adjusted duty cycle range.

2. The surgical instrument system according to claim 1, wherein, The parameters of the motor system include a firing load.

3. The surgical instrument system according to claim 1 or claim 2, wherein, The parameters of the motor system include the position of the firing member.

4. The surgical instrument system according to any one of the preceding claims, wherein, The parameters of the motor system include the actual measured speed of the firing member.

5. The surgical instrument system according to any one of the preceding claims, wherein, The parameters of the motor system include the actual measured speed of the motor.

6. The surgical instrument system according to claim 5, wherein, When it is detected that the motor is decelerating, the adjusted duty cycle range includes a first range, and wherein, when it is detected that the motor is accelerating, the adjusted duty cycle range includes a second range different from the first range.

7. The surgical instrument system according to any one of the preceding claims, wherein, The parameters of the motor system include motor current.

8. The surgical instrument system according to any one of the preceding claims, wherein, The staple firing stroke includes an active stroke portion and an inactive stroke portion, and wherein adjustments to the duty cycle range are restricted during the inactive stroke portion.

9. The surgical instrument system according to any one of the preceding claims, wherein, The control circuit is further configured to be able to adjust any combination of the proportional, integral, and derivative tuning parameters of the motor controller based on the monitored parameters during the staple firing stroke.

10. The surgical instrument system according to any one of the preceding claims, wherein, The magnitude of the adjustment to the duty cycle range is based on the magnitude of the monitored parameter.

11. The surgical instrument system according to any one of the preceding claims, wherein, The magnitude of the adjustment to the first set of parameters is based on the rate at which the monitored parameter changes during a portion of the staple firing stroke.

12. A surgical instrument system, the surgical instrument system comprising: A motor system, the motor system comprising: A motor; and A drive train that is couplable to the motor and is configured to be able to actuate a firing member through a staple firing stroke; and A control circuit coupled to the motor, wherein the control circuit includes a motor controller configured to be able to control the motor, and wherein, during the staple firing stroke, the control circuit is configured to be able to: Actuate the firing member through the staple firing stroke; Monitor parameters of the motor system during the staple firing stroke; Identify when the firing member is within an active adjustment portion of the staple firing stroke; and Automatically adjust the tuning parameters of the motor controller at a certain frequency based on the monitored parameters of the motor system during the active adjustment portion of the staple firing stroke.

13. The surgical instrument system according to claim 12, wherein, The parameters of the motor system include the load applied to the firing member.

14. The surgical instrument system according to claim 12 or claim 13, wherein, The parameters of the motor system include the position of the firing member.

15. The surgical instrument system according to any one of claims 12 to 14, wherein, The parameters of the motor system include the actual measured speed of the firing member.

16. The surgical instrument system according to any one of claims 12 to 15, wherein, The parameters of the motor system include the actually measured speed of the motor.

17. The surgical instrument system according to claim 16, wherein, When it is detected that the motor is decelerating and accelerating, the tuning parameters are adjusted in different ways.

18. The surgical instrument system according to any one of claims 12 to 17, wherein, The tuning parameters include any combination of the proportional, integral, and derivative tuning parameters of the motor controller.

19. The surgical instrument system according to any one of claims 12 to 18, wherein, The magnitude of the adjustment made to the tuning parameters is based on the rate at which the monitored parameter changes during a portion of the firing stroke.

20. A surgical instrument system, the surgical instrument system comprising: A motor system, the motor system comprising: A motor; and A drive train that is couplable to the motor and is configured to be able to actuate a firing member through a firing stroke; and A control circuit coupled to the motor, wherein the control circuit includes a motor controller configured to be able to control the motor, and wherein, during the firing stroke, the control circuit is configured to be able to: Monitor the position of the firing member; Determine a stage of the firing stroke in which the firing member is positioned based on the monitored position of the firing member; and Adjust motor control parameters according to the determined stage of the firing stroke to control the rate at which the speed of the firing member changes during the determined stage of the firing stroke, wherein the motor control parameters are configured to be adjusted in different ways for different stages of the firing stroke.

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