Surgical system including battery and control module

Abstract

A powered surgical tool includes a handpiece including a motor and a battery and control module. The battery and control module includes a device housing having a recess for removably receiving the handpiece, the device housing defining a void space. The rechargeable battery module is disposed in the void space. The controller is configured to adjust power drawn from the rechargeable battery module based on a user input.

Description

Background Technology

[0001] Modular handheld powered surgical tools are ubiquitous in modern operating rooms. Exemplary powered surgical tools include bone drills, burrs, saws, and razors. Modular handheld powered surgical tools typically include a handpiece component that includes a motor sized to meet the needs of surgical procedures, such as the removal of cortical bone and other hardened anatomical structures. Modular handheld powered surgical tools typically also include a device housing configured to connect to and power the motor of the handpiece component. As the applications of modular handheld powered surgical tools continue to evolve, it is important that these tools include a device housing capable of housing and identifying multiple devices.

[0002] Therefore, there is a need in the art for a handheld powered surgical tool that can identify various devices and provide them with power. Summary of the Invention

[0003] In a first aspect, a powered surgical tool is provided. The powered surgical tool includes: a handpiece including a motor and a tool connector, the handpiece defining at least one of a guide rail and a slot, and the handpiece further defining a receiver surface; and a battery and control module including: a device housing including another of a guide rail and a slot, the guide rail and slot being configured such that the guide rail can slide within the slot to allow connection between the handpiece and the battery and control module, the device housing further defining a clearance space; a rechargeable battery module disposed in the clearance space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further including a motor sensor configured to output a motor sensor signal indicating the state of the motor; and at least three conductive terminals extending through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece.

[0004] In a second aspect, a powered surgical tool is provided. The powered surgical tool includes: a handpiece including a motor and a tool connector, wherein the handpiece defines a cannula; and a battery and control module including: a device housing defining a clearance space; a rechargeable battery module disposed in the clearance space; a printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further including a motor sensor configured to output a motor sensor signal indicating the state of the motor; and at least three conductive terminals extending through the device housing for establishing an electrical connection between the printed circuit board assembly and the handpiece, wherein the battery and control module do not have a cannula.

[0005] In a third aspect, a surgical handpiece is provided for connection to a battery and a control module. The surgical handpiece includes: a housing; a tool connector; an electric motor disposed within the housing; a rotor defining an axis and connected to the electric motor and the tool connector; a rigid circuit board including a controller disposed within the housing and oriented perpendicular to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the rigid circuit board.

[0006] In a fourth aspect, a surgical handpiece is provided for connection to a battery and a control module. The surgical handpiece includes: a housing; a tool connector; an electric motor disposed within the housing; a rotor defining an axis that is connected to the electric motor and the tool connector; a circuit board including a controller disposed within the housing, the circuit board including a rigid portion and a flexible portion, the rigid portion defining an axis oriented parallel to the axis of the rotor; and a plurality of terminals extending through the housing and engaging the flexible portion of the circuit board.

[0007] In a fifth aspect, a powered surgical tool is provided. The powered surgical tool includes: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a first printed circuit board disposed in the void space and being rigid; a second printed circuit board disposed in the void space and being rigid, the second printed circuit board being coupled to the first printed circuit board, the second printed circuit board and the first printed circuit board being arranged in a stacked configuration, a plurality of motor control sensors being connected to the second printed circuit board; and a controller configured to regulate the power drawn from the rechargeable battery module based on user input, the controller being mounted to one of the first printed circuit board and the second printed circuit board.

[0008] In a sixth aspect, a powered surgical tool is provided. The powered surgical tool includes: a handpiece including a motor; and a battery and control module including: a device housing having a recess for removably receiving the handpiece, the device housing defining a void space; a rechargeable battery module disposed in the void space; a printed circuit board assembly disposed in the void space, the printed circuit board assembly including a rigid portion; a plurality of motor control sensors disposed on the rigid portion of the printed circuit board assembly; and a controller configured to regulate the power drawn from the rechargeable battery module based on user input, the controller being mounted to the printed circuit board assembly.

[0009] In a seventh aspect, a powered surgical tool is provided. The powered surgical tool includes: a handpiece including a motor comprising a plurality of magnets; and a control module including: a device housing for detachably receiving the handpiece, the device housing defining a clearance space; a first terminal; a sensor configured to provide a sensor signal, the sensor being positioned to sense at least one of the plurality of magnets when the handpiece is received; and a controller configured to adjust the power supplied to the first terminal based on the sensor signal.

[0010] In an eighth aspect, a powered surgical tool with a pencil-grip configuration is provided. The powered surgical tool includes: a plastic housing defining an integral mounting base defining a first orifice and a second orifice, a first pin and a second pin extending through the first orifice and the second orifice respectively, wherein the first pin defines a pivot axis and a pivot surface, and the first pin and the second pin define a press-fit engagement with each other; and a lever pivotally connected to the pivot surface of the first pin.

[0011] In the ninth aspect, a powered surgical tool is provided. The powered surgical tool includes: a housing defining a gap; a circuit board disposed in the gap of the housing for regulating the operation of an electric motor; a rechargeable battery module disposed within the gap; at least three motor pins spaced apart from each other to define a motor pin array extending through the housing and out of the gap for establishing an electrical connection between the circuit board and the electric motor, wherein an hermetically sealed housing-terminal interface is defined by the housing and the at least three motor pins; a layout feature disposed around the at least three motor pins, the layout feature defining a plurality of channels; at least three wires (or wires), each of the three wires including a wire terminal connected to a first wire end of the at least three wires and another end of the wire connected to the circuit board, each wire terminal including a first end portion and a second end portion opposite to the first end portion, the first end portion being connected to one of the at least three wires, and the second end portion being shaped to electrically engage one of the motor pins, each of the wire terminals being positioned within one of the channels of the layout feature.

[0012] In a tenth aspect, a powered surgical tool is provided. The powered surgical tool includes: a handpiece including a motor; a module housing configured to be coupled to one of the handpiece and a charging module, wherein each of the handpiece and the charging module is configured to generate a magnetic field; a printed circuit board assembly including a digital Hall effect sensor configured to sense the magnetic field; an analog Hall effect sensor configured to sense the magnetic field; and a controller configured to operate in a sleep state and an active state: in the sleep state, the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; in the active state, the analog Hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has been coupled to one of the handpiece and the charging module based on the magnetic field being sensed by the analog Hall effect sensor.

[0013] In an eleventh aspect, a system for identifying a device connected to a powered surgical tool is provided. The system includes: a handheld component configured to generate a magnetic field; a charging module configured to generate a magnetic field; and a powered surgical tool including: a module housing configured to connect to one of the handheld component and the charging module; and a printed circuit board assembly including: a digital Hall effect sensor configured to sense a magnetic field; an analog Hall effect sensor configured to sense a magnetic field; and a controller configured to operate in a sleep state and an active state: in the sleep state, the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; in the active state, the analog Hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing has been connected to one of the handheld component and the charging module based on the magnetic field being sensed by the analog Hall effect sensor.

[0014] In a twelfth aspect, a powered surgical tool is provided. The powered surgical tool includes: a first handpiece including a motor; a second handpiece including a motor; a module housing configured to connect to one of the first and second handpieces, wherein each of the handpieces and the charging module is configured to generate a magnetic field; and a printed circuit board assembly including: a digital Hall effect sensor configured to sense the magnetic field; an analog Hall effect sensor configured to sense the magnetic field; and a controller configured to operate in a sleep state and an active state: in the sleep state, the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; in the active state, the analog Hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing is connected to one of the handpieces and the charging module based on the magnetic field being sensed by the analog Hall effect sensor.

[0015] In a thirteenth aspect, a system for identifying a device connected to a powered surgical tool is provided. The system includes: a handheld component configured to generate a magnetic field; a charging module coupled to a charging adapter configured to generate a magnetic field; and a powered surgical tool including: a module housing configured to be connected to one of the handheld component and the charging module; and a printed circuit board assembly including: a digital Hall effect sensor configured to sense a magnetic field; an analog Hall effect sensor configured to sense a magnetic field; and a controller configured to operate in a sleep state and an active state: in the sleep state, the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; in the active state, the analog Hall effect sensor is active; wherein the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and wherein the controller is configured to determine whether the module housing is connected to one of the handheld component and the charging adapter based on the magnetic field being sensed by the analog Hall effect sensor.

[0016] In a fourteenth aspect, a surgical handpiece is provided for coupling to a battery and a control module. The surgical handpiece includes: a housing; an electric motor disposed within the housing and including a rotor, the rotor including an output shaft defining a longitudinal axis, the output shaft being coupled to the electric motor at a first end and configured to be coupled to a surgical tool at a second end, wherein the output shaft defines an inner cavity centered on the longitudinal axis of the output shaft; a cannula partially disposed within the inner cavity and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing and configured to prevent liquid from entering the interior of the surgical handpiece, wherein the cannula passes through the sealing plug; a seal disposed around the exterior of the cannula; and a plurality of terminals extending through the sealing plug.

[0017] In a fifteenth aspect, a powered surgical tool is provided. The powered surgical tool includes: a surgical handpiece comprising: a housing; an electric motor disposed within the housing and including a rotor, the rotor including an output shaft defining a longitudinal axis, the output shaft being coupled to the electric motor at a first end and configured to attach to the surgical tool at a second end, wherein the output shaft defines a cavity centered on the longitudinal axis of the output shaft; a cannula partially disposed within the cavity and extending from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; a sealing plug connected to the housing, wherein the cannula passes through the sealing plug; and a seal disposed around the exterior of the cannula. The powered surgical tool further includes: a plurality of terminals extending through the sealing plug, and a battery and a control module including a modular cavity configured to receive the surgical handpiece.

[0018] In a sixteenth aspect, a charging system is provided for charging a rechargeable battery module of a powered surgical tool, the powered surgical tool including a module housing configured to receive a handpiece. The charging system includes: a charger including a recess; and an adapter including: a charger protrusion configured to be received by the recess, wherein the recess includes a surface facing a first direction; and a module protrusion configured to be received by the module housing to allow the charger to provide power to the rechargeable battery module via the adapter, wherein the module protrusion extends in a direction different from the first direction.

[0019] In a seventeenth aspect, a charging system is provided for charging a rechargeable battery module of a first powered surgical tool (pencil grip type) and a rechargeable battery module of a second powered surgical tool (pistol grip type), wherein the first and second powered surgical tools each include a module housing configured to receive a handpiece. The charging system includes: a charger including a recess; and an adapter including: a charger protrusion configured to be received by the recess; and a module protrusion configured to be received by the module housing of the first powered surgical tool to allow the charger to provide power to the rechargeable battery module of the first powered surgical tool via the adapter; and to be received by the module housing of the second powered surgical tool to allow the charger to provide power to the rechargeable battery module of the second powered surgical tool via the adapter.

[0020] In an eighteenth aspect, a charging system is provided. The charging system includes: a charger including a recess; an adapter including: a charger protrusion configured to receive from the recess; a module protrusion; and a magnet disposed on the module protrusion, the magnet configured to generate a magnetic field; and a first powered surgical tool including: a first module housing configured to receive the module protrusion, the first module housing including a first end and a second end; a first Hall sensor located at a first distance from the first end of the module housing; and a first controller configured to transition from a sleep state to an active state based on the first Hall sensor sensing a magnetic field. The first controller is configured to communicate with the charger when the first controller is in the active state; the second powered surgical tool includes: a second module housing configured to receive the module protrusion, the second module housing including a first end and a second end; a second Hall sensor located at a second distance from the first end of the second module housing, the second distance being different from the first distance; and a second controller configured to transition from a sleep state to an active state based on the second Hall sensor sensing a magnetic field, wherein the second controller is configured to communicate with the charger when the second controller is in the active state.

[0021] In a nineteenth aspect, a charging system is provided. The charging system includes: a charger; a battery configured to receive power from the charger in response to contact with the charger; an adapter including: a charger protrusion configured to contact the charger; a module protrusion; and a magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; and a powered surgical tool including: a module housing configured to receive the module protrusion; a Hall sensor; and a controller configured to transition from a sleep state to an active state based on the Hall sensor sensing a magnetic field, wherein the controller is configured to communicate with the charger when the controller is in the active state.

[0022] In a twentieth aspect, a powered surgical tool is provided. The powered surgical tool includes a battery and a control module. The battery and control module include: a sealed housing assembly including a printed circuit board including at least one trigger sensor; a plurality of housings hermetically connected together and configured to enclose the printed circuit board and the at least one trigger sensor therein; and at least one trigger cavity configured to receive a trigger, wherein the at least one trigger sensor is disposed proximate to the at least one trigger cavity. The powered surgical tool also includes at least one trigger mounted within the at least one trigger cavity of the battery and control module, the at least one trigger including a rod portion configured to engage with the at least one trigger cavity, wherein the rod portion includes at least one magnet configured to interact with the at least one trigger sensor.

[0023] In a twenty-first aspect, a method of operating a powered surgical tool is provided. The method includes the steps of providing a battery and a control module comprising a sealed housing assembly, the housing assembly encapsulating a printed circuit board including at least one trigger sensor and including at least one trigger cavity configured to receive a trigger. The method further includes the step of mounting at least one trigger into the trigger cavity, the trigger including a rod portion having at least one magnet configured to interact with the trigger sensor without compromising the seal of the sealed housing assembly.

[0024] In a twenty-second aspect, a method for repairing a powered surgical tool is provided. The method includes the steps of providing a battery and a control module comprising a sealed housing assembly, the housing assembly encapsulating a printed circuit board including at least one trigger sensor, the battery and control module further comprising a trigger having a magnet. The method also includes the step of removing the trigger from the battery and control module without compromising the seal of the sealed housing assembly.

[0025] In some embodiments, the handheld component defines a sleeve, and the device housing does not have a sleeve. In some embodiments, the surgical handheld component defines a longitudinal axis, and the surgical handheld component defines a sleeve surrounding the longitudinal axis. In some embodiments, a rigid circuit board defines an aperture surrounding the sleeve. In some embodiments, the aperture and the sleeve are coaxial. In some embodiments, the battery and control module include a safety vent. In some embodiments, the battery and control module also includes a plurality of support ribs and a plate mount, the plate mount including a plurality of wings for engaging the support ribs. In some embodiments, the device housing defines a mounting post, and a third printed circuit board abuts against the mounting post such that the axial position of the third printed circuit board is controlled within the battery and control module. In some embodiments, the battery and control module also includes a plate mount including one of a set of recesses or a set of protrusions, and the device housing defines the other of the set of recesses or protrusions, wherein the set of protrusions engages the set of recesses to prevent the plate mount from moving relative to the device housing in multiple degrees of freedom. In some embodiments, the battery and control module further include a board mount, wherein the board mount includes one of a set of recesses or a set of protrusions, and a device housing defines the other of the set of recesses or protrusions, wherein the set of protrusions engages the set of recesses to prevent rigid portions of the printed circuit board assembly from moving relative to the device housing in two or more degrees of freedom. In some embodiments, the set of recesses and / or the set of protrusions are positioned relative to each other in an arcuate arrangement. In some embodiments, the board mount includes the set of protrusions, and each of the set of protrusions defines a slot for securing one of a plurality of motor control sensors. In some embodiments, the board mount includes a body portion and a flange defining a hole for inserting a fastener, the flange extending perpendicularly from the body portion. In some embodiments, the battery and control module further includes a plurality of spacers disposed between a first printed circuit board and a second printed circuit board. In some embodiments, each of the plurality of spacers defines a hole, wherein the battery and control module includes a plurality of fasteners arranged to extend through the hole in at least one of the plurality of spacers and the second printed circuit board. In some embodiments, the plate mount defines a plurality of mounting holes, each of which includes a threaded insert. In some embodiments, the battery and control module includes a latch assembly comprising a locking member and a biasing member positioned to push the locking member toward the receiver surface.

[0026] In some embodiments, the motor is an electric motor. In some embodiments, the motor sensor is further defined as a Hall effect sensor. In some embodiments, the motor includes a plurality of magnets, and the device housing includes a set of notches defining a series of notch peaks and notch valleys, wherein the innermost surface of the notch peaks is further away from the magnets of the motor than the innermost surface of the notch valleys. In some embodiments, the sensor is further defined as a first set of sensors axially aligned with at least a portion of one of the plurality of magnets when the handpiece is received in the control module. In some embodiments, the first set of sensors is a digital Hall effect sensor. In some embodiments, the powered surgical tool further includes a second set of sensors, wherein the second set of sensors is an analog Hall effect sensor. In some embodiments, the controller is configured to energize a first terminal based on the first set of sensors, and wherein the controller is configured to commutate the motor based on the second set of sensors. In some embodiments, each sensor in the first set of sensors is aligned with each other. In some embodiments, each sensor in the second set of sensors is aligned with each other. In some embodiments, the first set of sensors is axially biased from the second set of sensors. In some embodiments, the motor includes a motor rotor, a stack of laminations surrounding the rotor, and a plurality of magnets surrounding the rotor, wherein a portion of the plurality of magnets extends axially beyond the stack of laminations.

[0027] In some embodiments, the controller is configured to transition between a sleep state and an active state, wherein the powered surgical tool is configured to transition the controller from a sleep state to an active state based on sensor signals. In some embodiments, the powered surgical tool further includes a second terminal that is energized when the controller is in either the sleep or active state. In some embodiments, when the controller is in the sleep state, the powered surgical tool has a current consumption of less than 5 mA.

[0028] In some embodiments, the battery and control module further includes a third printed circuit board (PCB) connected via a conductor to one of the first and second PCBs, wherein the third PCB includes at least three conductive terminals that extend at least partially through the device housing for establishing an electrical connection between the third PCB and the handheld device. In some embodiments, the handheld device includes a memory device electrically connected to at least one of a plurality of terminals. In some embodiments, the handheld device includes a memory device electrically connected to at least one of the at least three conductive terminals. In some embodiments, the at least three conductive terminals are soldered to the third PCB. In some embodiments, the conductor is further defined as a flexible circuit. In some embodiments, the first PCB has a larger surface area than the second PCB. In some embodiments, when the handheld device is coupled to the battery and control module, the first PCB is further away from the motor than the second PCB. In some embodiments, the first and second PCBs are interconnected using a board connector (or board header). In some embodiments, the second PCB includes two main sides, wherein a board mount contacts only one of the two main sides. In some embodiments, the second PCB includes at least four secondary sides, wherein a board mount contacts two or fewer secondary sides of the second PCB. In some embodiments, the second printed circuit board includes at least four secondary sides, wherein the board mount does not contact the secondary sides of the second printed circuit board. In some embodiments, the third printed circuit board includes a light source, and the device housing includes a light guide aligned with the light source. In some embodiments, the handheld device includes a memory device and a data terminal, the data terminal being in electrical communication with the memory device, and wherein the data terminal is configured to connect to a second terminal of the control module when the handheld device is received in the recess.

[0029] In some embodiments, the distal end face of the handpiece is exposed when it is connected to the battery and control module. In some embodiments, a portion of the proximal end face of the handpiece is exposed when it is connected to the battery and control module.

[0030] In some embodiments, a plastic housing defines a first recess adjacent to a first orifice, the first recess including a first flat surface, a first pin including a head and a shaft extending from the head, the head including a second flat surface, the first pin being positioned within the first orifice such that the second flat surface of the head engages the first flat surface of the first recess. In some embodiments, the plastic housing defines a channel in which a lever is pivotable about the first pin between a first fully pressed position and a second unpressed position, and in both the first fully pressed position and the second unpressed position, the lever is at least partially disposed within the channel. In some embodiments, at least one of at least three motor pins defines a longitudinal axis, and a circuit board defines a longitudinal axis, wherein the longitudinal axis of the at least one motor pin is parallel to the longitudinal axis of the circuit board. In some embodiments, the at least three motor pins are further defined as at least six motor pins, and wherein the at least three wires are further defined as at least six wires. In some embodiments, the at least six motor pins are positioned equidistant from the center of the array.

[0031] In some embodiments, the powered surgical tool further includes: a handpiece including a motor; and wherein the plastic housing defines a recess for removably receiving the handpiece, the plastic housing defining a void space; a printed circuit board disposed in the void space; a rechargeable battery module disposed in the void space; a lever configured to receive input from a user to draw power from the rechargeable battery module and supply it to the motor, wherein the powered surgical tool has a pencil-grip type configuration; and wherein the plastic housing includes a controller configured to regulate the power drawn from the rechargeable battery module based on movement of the lever. In some embodiments, the powered surgical tool further includes a manual switch sensor configured to output a manual switch sensor signal based on the position of the lever, wherein the controller is configured to receive the manual switch sensor signal and regulate the power drawn from the rechargeable battery module based on the manual switch sensor signal. In some embodiments, the manual switch sensor is further defined as a first manual switch sensor, and the manual switch sensor signal is further defined as a first manual switch sensor signal. The powered surgical tool also includes a second manual switch sensor configured to output a second manual switch sensor signal based on the lever's position. A controller is configured to receive the second manual switch sensor signal and adjust the power drawn from the rechargeable battery module based on the first and second manual switch sensor signals. In some embodiments, the first and second manual switch sensors are each mounted on opposite surfaces of a printed circuit board, and the controller is disposed on the printed circuit board. In some embodiments, the lever includes an operating safety switch slidably mounted to the lever, a magnet mounted to the operating safety switch, and a lever extension movably coupled to the lever. The manual switch sensor is a Hall effect sensor.

[0032] In some embodiments, the powered surgical tool also includes a torsion spring comprising a coil, a first leg, and a second leg, wherein the first leg and the second leg extend from opposite ends of the coil, and wherein the coil surrounds a first pin.

[0033] In some embodiments, the arrangement features define an edge portion that defines a plurality of channels and surrounds at least three motor pins. In some embodiments, a first end portion of the wire terminal is disposed inside the edge portion, and a second end portion of the wire terminal is disposed outside the edge portion. In some embodiments, the wire terminal defines a bend of at least 70 degrees, wherein the first end portion of the wire terminal is separated from the second end portion of the wire terminal by the bend portion. In some embodiments, the plurality of channels includes a first channel and a second channel, wherein the first channel has a first depth and the second channel includes a second depth, the first depth being different from the second depth. In some embodiments, the first end portion of at least one of the wire terminals defines a plurality of arms, each arm being crimped to engage a first wire end. In some embodiments, the second end portion of the wire terminal defines a cylindrical gap that surrounds the motor pins.

[0034] In some embodiments, the control module is further defined as a battery and a control module, wherein the battery and control module also include a rechargeable battery module. In some embodiments, the powered surgical tool includes a rechargeable battery module, wherein a digital Hall effect sensor is configured to receive power from the rechargeable battery module in a sleep state, and wherein an analog Hall effect sensor is configured to receive power from the rechargeable battery in an active state. In some embodiments, the amount of power received by the analog Hall effect sensor from the rechargeable battery in the active state is greater than the amount of power received by the digital Hall effect sensor in the sleep state.

[0035] In some embodiments, the controller is configured to: communicate with the handheld device using a first communication protocol in response to determining that the module housing has been connected to the handheld device; and communicate with the charging module using a second communication protocol in response to determining that the module housing has been connected to the charging module. In some embodiments, the controller is configured to communicate using the first communication protocol at a first transmission speed, and wherein the controller is configured to communicate using the second communication protocol at a second transmission speed. In some embodiments, the controller is configured to communicate using the first communication protocol using full-duplex transmission, and wherein the controller is configured to communicate using the second communication protocol using half-duplex transmission.

[0036] In some embodiments, the controller is configured to send a communication signal to the handheld device based on determining that the module housing has been connected to the handheld device. In some embodiments, the controller is configured to transmit a communication signal to the charging module based on determining that the module housing has been connected to the charging module. In some embodiments, the controller is configured to receive a communication signal from the programming fixture based on determining that the module housing has been connected to the programming fixture.

[0037] In some embodiments, the module housing is also configured to be coupled to a programming fixture, wherein the programming fixture is configured to generate a magnetic field, and wherein the controller is configured to determine whether the module housing has been coupled to the programming fixture based on the magnetic field being sensed by a simulated Hall effect sensor.

[0038] In some embodiments, the analog Hall effect sensor is further defined as a first analog Hall effect sensor, wherein the printed circuit board assembly also includes a second analog Hall effect sensor and a third analog Hall effect sensor. In some embodiments, the handheld device also includes a motor, which includes a first rotor magnet and a second rotor magnet, each configured to generate a magnetic field to cause rotation of the motor; the first, second, and third analog Hall effect sensors are each configured to sense the magnetic field generated by the first and second rotor magnets; the controller is configured to transition from a sleep state to an active state based on the magnetic field sensed by the digital Hall effect sensor and generated by the first and second rotor magnets; and the controller is configured to determine that the module housing has been connected to the handheld device based on the magnetic field sensed by the first, second, and third analog Hall effect sensors and generated by the first and second rotor magnets.

[0039] In some embodiments, the system further includes a programming fixture comprising a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; a simulated Hall effect sensor is configured to sense the magnetic field by sensing the magnitude of the magnetic field; and the positions of the magnets of the programming fixture and the magnets of the charging module are selected such that the magnitude of the first magnetic field sensed by the simulated Hall effect sensor is different from the magnitude of the second magnetic field sensed by the simulated Hall effect sensor.

[0040] In some embodiments, the system further includes a programming fixture comprising a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; a simulated Hall effect sensor is configured to sense the magnetic field by sensing the polarity of the magnetic field; and the polarity of the magnet of the programming fixture and the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the simulated Hall effect sensor is different from the polarity of the second magnetic field sensed by the simulated Hall effect sensor. In some embodiments, the system further includes a programming fixture comprising a magnet configured to generate a first magnetic field, wherein: the charging module includes a magnet configured to generate a second magnetic field; a simulated Hall effect sensor is configured to sense the magnetic field by sensing the polarity of the magnetic field; and the polarity of the magnet of the programming fixture and the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the simulated Hall effect sensor is different from the polarity of the second magnetic field sensed by the simulated Hall effect sensor.

[0041] In some embodiments, the charger includes two recesses, and the adapter includes two charger protrusions configured to engage the two recesses. In some embodiments, the adapter includes two module protrusions. In some embodiments, each recess includes a width; each module protrusion includes a width; and the sum of the widths of the module protrusions is less than the width of the recess. In some embodiments, the two charger protrusions of the adapter are disposed along a first direction, and the two module protrusions are disposed along a second direction different from the first direction.

[0042] In some embodiments, the module protrusion includes: a first latch configured to engage an interface of a module housing of a first powered surgical tool; and a second latch configured to engage an interface of a module housing of a second powered surgical tool. In some embodiments, the module protrusion includes a first portion shaped to be received by a module housing of the first powered surgical tool; and a second portion shaped to be received by a module housing of the second powered surgical tool. In some embodiments, the module housing of the first powered surgical tool includes a first radius; the module housing of the second powered surgical tool includes a second radius different from the first radius; the first portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the first powered surgical tool; and the second portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the second powered surgical tool. In some embodiments, the module protrusion includes: a first latch disposed on the first portion, configured to engage an interface of a module housing of the first powered surgical tool; and a second latch disposed on the second portion, configured to engage an interface of a module housing of the second powered surgical tool.

[0043] In some embodiments, a first Hall sensor is configured to sense a magnetic field generated by a magnet in response to a first module housing receiving module protrusion. In some embodiments, a second Hall sensor is configured to sense a magnetic field generated by a magnet in response to a second module housing receiving module protrusion.

[0044] In some embodiments, the controller is configured to communicate using a first communication protocol, and the charger is configured to communicate using a second communication protocol, wherein the adapter is configured to convert one of the first and second communication protocols into the other of the second and first communication protocols, such that the controller is configured to communicate with the charger via the adapter. In some embodiments, the charger includes charger power terminals and charger communication terminals, wherein a charger protrusion includes an adapter communication contact configured to contact the charger communication terminals and an adapter power contact configured to contact the charger power terminals, wherein a module protrusion includes a first adapter communication terminal and a second adapter communication terminal communicating with the adapter communication contacts, and wherein the first and second adapter communication terminals are short-circuited to each other, such that the controller is configured to communicate with the charger via the adapter. In some embodiments, the controller is configured to communicate using the first communication protocol via full-duplex transmission, and the charger is configured to communicate using the second communication protocol via half-duplex transmission; and the adapter is configured to convert the second communication protocol to the first communication protocol by converting half-duplex transmission to full-duplex transmission.

[0045] In some embodiments, the second distal end includes a tool connector. In some embodiments, the cavity centered on the longitudinal axis of the output shaft is a first cavity; wherein the seal includes a cylindrical shape having a second cavity; and wherein the sleeve is disposed within the second cavity. In some embodiments, the seal includes a first sealing surface on an end surface of the cylindrical shape, wherein the end surface abuts against a mating surface on a sealing plug. In some embodiments, the seal includes a second sealing surface, the second sealing surface including an annular (ring-shaped) surface on the inner diameter of the seal, the annular surface abutting against the outer surface of the sleeve. In some embodiments, the sealing plug includes a polymer. In some embodiments, the housing includes an internal structure insert disposed within the housing and including an inner diameter at a first proximal end of the surgical handpiece; and wherein the sealing plug is press-fitted within the inner diameter of the internal structure insert. In some embodiments, the surgical handpiece further includes a port stop disposed around the exterior of the internal structure insert and the sealing plug, wherein the port stop is configured to retain the sealing plug within the inner diameter of the internal structure insert. In some embodiments, the seal is configured to contact a sleeve flange.

[0046] In some embodiments, the battery and control module further include a cannula access point configured to allow external access to a cannula within a first proximal end of the surgical handgrip. In some embodiments, a second distal end includes a tool connector. In some embodiments, the seal includes a cylindrical shape with a hollow portion; and the cannula is disposed within the hollow portion of the seal. In some embodiments, the seal includes a first sealing surface on an end surface of the cylindrical shape that abuts against a mating surface on a sealing plug; and the seal includes a second sealing surface that includes an annular ring on the inner diameter of the seal that abuts against an outer surface of the cannula. In some embodiments, the battery and control module define a pistol grip.

[0047] In some embodiments, the at least one trigger cavity includes a trigger vent cutout formed in the wall of the at least one trigger cavity, the trigger vent cutout being formed in the surface of the wall without compromising the seal of the sealed housing assembly, and the trigger vent cutout being configured to allow air to be released from behind the at least one trigger when the at least one trigger is pressed or installed. In some embodiments, at least one trigger is held in at least one trigger cavity by screws and a front plate, and the screws and front plate enable replacement of at least one trigger without compromising the seal of the sealed housing assembly. In some embodiments, the sealed housing assembly includes two trigger cavities, and the powered surgical tool further includes two triggers. In some embodiments, the sealed housing assembly also includes a battery comprising at least one battery cell. In some embodiments, the sealed housing assembly also includes a handpiece cavity configured to receive a handpiece including a modular motor configured to supply power to a surgical end effector. In some embodiments, the at least one trigger sensor is configured to detect the at least one magnet through one of the plurality of housings. In some embodiments, the plurality of housings that are sealed together are welded together by either vibration welding or laser welding.

[0048] Other applications of this disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0049] The advantages of this disclosure will be readily apparent, as they become even more readily understood by taking into account the accompanying drawings and the following detailed description.

[0050] Figure 1This is a perspective view of a first embodiment of a powered surgical tool according to the teachings of this disclosure, showing the battery and control module spaced apart from the surgical handpiece.

[0051] Figure 2 yes Figure 1 A perspective view of the control module.

[0052] Figure 3 yes Figure 2 Side view of the control module.

[0053] Figure 4 yes Figure 2 An exploded view of the control module.

[0054] Figure 5 yes Figure 4 A perspective view of the printed circuit board assembly.

[0055] Figure 6 yes Figure 5 A top view of the printed circuit board assembly.

[0056] Figure 7 yes Figure 5 A front view of the printed circuit board assembly.

[0057] Figure 8 yes Figure 5 An exploded view of the printed circuit board assembly.

[0058] Figure 9 It depicts the teachings of this disclosure. Figure 2 The rear perspective view of the front of the control module.

[0059] Figure 10 Depicting Figure 3 A cross-sectional view of the control module.

[0060] Figure 11 Depicting Figure 4 A perspective view of the printed circuit board and layout components of the control module.

[0061] Figure 12 Depicting Figure 11 A perspective view of the layout components.

[0062] Figure 13 The wiring is not shown. Figure 12 The rear view of the layout components.

[0063] Figure 14 A perspective view of a second embodiment of a powered surgical tool is depicted, in which a second handpiece is connected to a battery and a control module.

[0064] Figure 15 Depicting Figure 14A cross-sectional view of the battery and control module.

[0065] Figure 16 Depicting Figure 14 First perspective view of the printed circuit board assembly of the battery and control module.

[0066] Figure 17 Depicting Figure 14 A second perspective view of the printed circuit board assembly of the battery and control module.

[0067] Figure 18A Depicting Figure 16 An exploded view of the first example of a printed circuit board assembly.

[0068] Figure 18B Depicting Figure 16 An exploded view of a second example of a printed circuit board assembly.

[0069] Figure 19 Depicting and Figure 14 The battery and part of the control module are adjacent. Figure 16 Rear perspective view of a portion of a printed circuit board assembly.

[0070] Figure 20 Depicting Figure 14 Rear perspective view of the battery and control module, in which Figure 16 The printed circuit board assembly was removed.

[0071] Figure 21 The teachings of this disclosure are shown. Figure 2 A cross-sectional view of the base portion of the first embodiment of the powered surgical tool.

[0072] Figure 22 Depicting Figure 1 A cross-sectional view of the battery and control module.

[0073] Figure 23 A perspective view depicting a third embodiment of a powered surgical tool is shown, in which a third handpiece is connected to a battery and a control module.

[0074] Figure 24 Depicting Figure 23 Rear perspective view of the third embodiment of the powered surgical tool shown.

[0075] Figure 25 Depicting Figure 23 The diagram shows a front perspective view of a third embodiment of the powered surgical tool, in which the third handpiece has been removed.

[0076] Figure 26 Depicting Figure 23 Rear perspective view of the third handheld component.

[0077] Figure 27 It shows Figure 26 A perspective view of a portion of the interior of the third handpiece.

[0078] Figure 28 Depicting Figure 26 An external perspective view of the third handheld component.

[0079] Figure 29 Depicting Figure 26 A cross-sectional view of the third handpiece.

[0080] Figure 30 A cross-section of the fourth handpiece is depicted.

[0081] Figure 31 Depicting Figure 30 A perspective view of the fourth handheld component.

[0082] Figure 32 A perspective view depicting a portion of the interior of the fifth handpiece.

[0083] Figure 33 Depicting Figure 32 A cross-sectional view of the fifth handpiece.

[0084] Figure 34 yes Figure 1 A perspective view of the first embodiment of the battery and control module pins.

[0085] Figure 35 yes Figure 1 A perspective view of the second embodiment of the pins for the battery and control module.

[0086] Figure 36 This is a perspective view of the charging module and charging adapter, wherein the charging module is connected to the charging adapter via... Figure 1 The battery and control module and its connection with Figure 14 The battery and control module are connected.

[0087] Figure 37 yes Figure 36 A perspective view of the charging module and charging adapter, wherein the charging adapter is not received by the charging module.

[0088] Figure 38 yes Figure 36 A perspective view of the protruding module of the charging adapter.

[0089] Figure 39 yes Figure 36 An exploded view of the charging adapter.

[0090] Figure 40 yes Figure 36 A top view of the charging adapter.

[0091] Figure 41 yes Figure 1 Battery and control module, Figure 14 Battery and control module, Figure 36 The charging adapter and Figure 36 A schematic diagram of the charging module.

[0092] Figure 42 This is a perspective view of the programming fixture.

[0093] Figure 43 yes Figure 42 The front view of the programming fixture.

[0094] Figure 44 This is a schematic diagram of a system for identifying devices connected to powered surgical tools.

[0095] Figure 45 It shows the method for identifying and Figure 1 The diagram shows the operational status of the system of the device connected to the powered surgical tool.

[0096] Figure 46 This indicates when the battery and control module are not connected to the device. Figure 1 Battery and control module or Figure 14 A graph of the sensing readings of the analog Hall effect sensor of the battery and control module of module 23.

[0097] Figure 47 This shows when the battery and control module are connected to the handheld device. Figure 1 Battery and control module or Figure 14 A graph of the sensing readings of the analog Hall effect sensor of the battery and control module of module 23.

[0098] Figure 48 This shows when the battery and control module are connected to the handheld device. Figure 1 Battery and control module or Figure 14 A graphical representation of the ideal sensing readings of an analog Hall effect sensor with a battery and control module of 23.

[0099] Figure 49 This shows when the battery and control module are connected... Figure 36 When the charging module is connected Figure 1 Battery and control module or Figure 14 A graph of the sensing readings of the analog Hall effect sensor of the battery and control module of module 23.

[0100] Figure 50 This shows when the battery and control module are connected... Figure 42 and 43 When the programming fixture is connected Figure 1 Battery and control module or Figure 14A graph of the sensing readings of the analog Hall effect sensor of the battery and control module of module 23.

[0101] Figure 51 An exemplary battery and control module are schematically shown in the form of a previous perspective view.

[0102] Figure 52 The following perspective view is shown schematically. Figure 51 The battery and control module.

[0103] Figure 53 The side view schematically illustrates the configuration for attachment. Figure 51 Attachments to the battery and control module or surgical handheld devices.

[0104] Figure 54 Schematally shown in sectional view Figure 53 A surgical handpiece comprising a combination of a sealing plug and a sealing element configured to seal the interior of the surgical handpiece and prevent liquid from entering the interior.

[0105] Figure 55 An embodiment of a powered surgical tool is shown, wherein the housing of the battery and control module is designed to provide improved ergonomics and usability.

[0106] Figure 56 The side perspective view shows the contents corresponding to... Figure 55 The internal components of the trigger sensor, the battery, and the control module are a pair of trigger sensors.

[0107] Figure 57 The front housing is shown in a rear perspective view, configured for assembly, welding, laser process attachment, or other attachment to Figure 56 The handle portion of the middle housing.

[0108] Figure 58 The sealed housing assembly is shown in a side perspective view. The sealed housing assembly includes a front housing that is welded, laser-attached, adhesively bonded, fastened, or otherwise attached to the intermediate housing in a sealing manner.

[0109] Figure 59 Shown in the form of a side perspective view Figure 58 A sealed housing assembly to which a trigger is mounted.

[0110] Figure 60 It is shown in the disassembled state. Figure 59 The sealed housing components and triggers.

[0111] Figure 61A portion of the trigger and sealed housing assembly is shown in a side sectional view.

[0112] Figure 62 The previous sectional view showed a portion of the trigger and the sealed housing assembly.

[0113] Figure 63 The previous perspective view shows a portion of a sealed housing assembly including multiple trigger venting cutouts.

[0114] Figure 64 The previous sectional view shows a portion of the sealed housing assembly, including the rod section and the corresponding trigger vent.

[0115] Figure 65 This is a flowchart illustrating an example of a method for operating a powered surgical tool.

[0116] Figure 66 This is a flowchart illustrating an example of a method for repairing a powered surgical tool. Detailed Implementation

[0117] Figure 1 An embodiment of a powered surgical tool 20 is illustrated, wherein the device housing 22 of the battery and control module 21 is designed to provide improved ergonomics and usability. The powered surgical tool 20 includes a handpiece 24 configured to be detachably coupled to the battery and control module 21. The handpiece 24 may include a motor and drivetrain (not identified), as well as other sub-components such as an electrical connector, gearbox, and geometry for detachably receiving cutting attachments including a head. Apart from the specific features of the handpiece 24, which will be described in further detail, the handpiece 24 may take the form disclosed in commonly owned International Publication No. WO2013 / 177423, published November 28, 2013, the entire contents of which are incorporated herein by reference.

[0118] The cutting attachment assembly may be unique for the complementary form (or structure) of the motor and drivetrain, in order to provide a set of handholds configured to selectively and interchangeably connect with the battery and control module 21. See also... Figure 1The powered surgical tool 20 is shown having a connector 26 for attaching to a cutting attachment (such as a sagittal saw blade). Medical professionals can use a sagittal saw blade to cut bone, such as small bones, ligaments, or other tissues in a patient's hand or foot. Any device or attachment applied to the surgical site, whether a sagittal saw blade or a drill bit, can generally be referred to as an energy applicator. In other embodiments, the powered surgical tool 20 can be a rotary drill, reamer, wire driver, oscillating or reciprocating saw, ultrasonic device, or photonic device. Similarly, the energy applicator can be a drill bit, bone drill, saw, reamer, grinding disc, ultrasonic cutting or catheter insertion tip, laser, etc. The type of tool used is not intended to limit the invention. The motor can be a general-purpose motor that can interchangeably receive more than one cutting attachment, as described below. It should also be understood that the set of handpieces can be interchangeably configured with a pencil grip type (…). Figure 1-13 The battery and control module 21 provided are configured for a pistol grip type. Figure 14-23 The battery and control modules 221 and 421 provided in 23-25 ​​are connected. The powered surgical tool 20 of this disclosure is particularly suitable for orthopedic surgeries involving the arm, hand, leg, foot, mandible, and skull, but other small bone orthopedic and soft tissue surgeries are also conceivable. Figure 2 The battery and control module 21 with the handheld component removed are shown. Figure 3 A side view of the battery and control module 21 is shown.

[0119] refer to Figure 4 and 5 The battery and control module 21 includes at least one battery 28 and a main controller 31 coupled to the printed circuit board assembly 33, as will be discussed in more detail below. The main controller 31 communicates with the battery 28, which may be part of the battery assembly 30, the motor control sensor 32, and the manual switch sensor 34, and is also configured to communicate with the motor when the handheld device 24 is detachably coupled to the battery and control module 21. The main controller 31 may also communicate with the memory device 95 (e.g., Figure 8 (As shown) Communication. The battery and control module 21 may include a manual switch assembly 36, which may be optionally coupled to the device housing 22 and configured to receive input from a user to operate the powered surgical tool 20. For example, the manual switch assembly 36 may be spring-loaded and include a manual switch magnet such that when the manual switch assembly 36 is actuated, the manual switch magnet moves toward the manual switch sensor 34. While an example of the manual switch assembly 36 being coupled to the battery and control module 21 is provided, the manual switch assembly 36 may be detachable and attached to any part of the battery and control module 21 and / or the handheld device 24. Furthermore, the manual switch assembly 36 may be part of or attached to the handheld device 24.

[0120] The main controller 31 receives a signal from the manual switch sensor 34 and causes power to be drawn from at least one battery cell 28 to supply the motor. The main controller 31 is configured to determine the rotational position of the motor's rotor and control the motor based on the rotational position of the rotor sensed by the motor control sensor 32. In an alternative embodiment, one or more manual switch sensors 34 may be omitted, and the motor may be controlled in other ways. The operating speed of the powered surgical tool 20 can be incrementally increased when the manual switch assembly 36 is actuated between a default position and a fully engaged position. Other features of the main controller 31, the manual switch assembly 36, and other electronic sub-components of the powered surgical tool 20 may be disclosed in the aforementioned international publication WO2013 / 177423. The main controller 31 may be configured to regulate the power drawn from the rechargeable module based on the movement of lever 66.

[0121] The main controller 31 can also receive signals from the manual switch sensor 34.

[0122] In some instances, the manual switch sensor 34 is further defined as two manual switch sensors. Therefore, the controller can be configured to receive signals from both sensors and adjust the power drawn from the rechargeable battery module based on these signals. Both the first and second manual switch sensors 34 are mounted on the same surface of the printed circuit board 87 or on opposite sides of the printed circuit board 87. Therefore, the lever 66 can be configured to receive input from the user to draw power from the rechargeable battery module and supply it to the motor of the handheld device.

[0123] See now Figure 1 This illustrates a first embodiment of a powered surgical tool 20. A device housing 22 defines a recess 40 sized to detachably receive a handpiece 24. More specifically, the device housing 22 includes a front surface 42 defining an opening 44 that extends proximally to define the recess 40. The recess 40 may be at least substantially cylindrical to conform to the profile of a hub 46 of the handpiece 24. The hub 46 of the handpiece 24 is disposed within the recess 40 to establish communication between the motor of the handpiece 24 and the battery and control module 21. Several sub-components of the device housing 22 may be disposed within or adjacent to the recess 40 to releasably secure the handpiece 24 to the device housing 22 and establish communication between the motor and the main controller 31. The sub-components may include one or more motor pins 48 (e.g., providing a connection from the battery and control module 21 to the handpiece 24) Figure 4(As shown) or other terminal configurations. Such sub-components may also include latches and sensors, as discussed in more detail below. Some such sub-components are disclosed in the aforementioned international disclosure WO2013 / 177423, the contents of which have been previously incorporated herein by reference. Tool 20 may also include a light guide 63 for directing light from one or more light sources on the printed circuit board assembly to the user.

[0124] It should be noted that, although in Figure 1 In one example, the module housing 22 of the battery and control module 21 receives the handheld component 24; however, in other examples, the handheld component 24 may be configured to receive components of the battery and control module 21. For example, the handheld component 24 may define a recess sized to detachably receive the module housing 22 of the battery and control module 21.

[0125] The device housing 22 may also define a recess for positioning the latch assembly 52. ​​The latch assembly 52 may include a locking member 54 and a biasing member.

[0126] As previously described, the manual switch assembly 36 can be connected to the device housing 22. (Reference) Figure 4 The device housing 22 may define a mounting base 56. The mounting base 56 may be integral with the device housing. Furthermore, both the device housing 22 and the integral mounting base 56 may be formed of a plastic material. The mounting base 56 may define orifices 58 adjacent to and located on one side of the manual switch recess 50. The manual switch assembly 36 may be partially housed within the manual switch recess 50 or channel.

[0127] The length of the manual switch assembly 36 is adjustable relative to the device housing 22. The manual switch assembly 36 may also include a pressing pin 60 and a receiving pin 62. Each of the pins 60, 62 extends through one of the orifices 58. During assembly, the pressing pin 60 is pressed into the orifice defined by the receiving pin 62. Once these pins are pressed into each other, the receiving pin defines a pivot axis 64 and a pivot surface. Thus, the pressing pin 60 and the receiving pin 62 define a press-fit engagement with each other. The manual switch assembly 36 also includes a lever 66 pivotally coupled to the pivot surface of the receiving pin 62. The lever 66 may define an orifice for receiving the receiving pin, such that the lever 66 pivots about the receiving pin 62. When the plastic housing defines a channel, the lever 66 may pivot about the receiving pin 62 between a first fully pressed position and a second unpressed position, wherein in both the first fully pressed position and the second unpressed position, the lever 66 is at least partially disposed within the manual switch recess 50 or channel.

[0128] refer to Figure 3 and 4In some instances, the device housing 22 defines a recess 68. The recess 68 is positioned adjacent to an orifice 58, and includes a flat surface 70, wherein the receiving pin 62 optionally includes a head 72 and a shaft 74 extending from the head 72. The head 72 includes a flat pin surface 76, and the receiving pin 62 is positioned within the orifice 58 such that the flat pin surface 76 of the head 72 engages the flat surface 70 of the recess 68. It is contemplated that a press pin may include similar features regarding the head and shaft and the flat surface, and another orifice 58 may include a similar recess having a similar flat surface. The engagement of the pin flat surface 76 and the flat surface 70 of the recess 68 contacts each other to prevent rotation of the receiving pin relative to the device housing 22.

[0129] Continue to refer to Figure 4 The manual switch assembly 36 may also include a biasing member, such as a torsion spring 78. The torsion spring 78 includes a coil 80 and two legs 82 extending from opposite ends of the coil 80. The coil 80 is positioned about a pivoting surface of the receiving pin 62.

[0130] The lever 66 may also include a running safety switch 84 slidably mounted to the lever 66, a switch magnet mounted to the running safety switch, and a lever extension movably connected to the lever 66. When the running safety switch 84 is in the "running" position and the user presses the lever, the magnet moves up and down. The Hall sensor voltage of the manual switch sensor changes in response to the magnet moving closer or further away. This voltage change is used to control the speed. When the running safety switch is in the "safe" position, the magnet moves forward as if it were out of sensing range. Therefore, it is ensured that even if the user presses the lever, the manual switch sensor will not see a meaningful voltage change. Therefore, the handpiece will not operate.

[0131] refer to Figure 5-7The printed circuit board assembly 33 may include a board mount 86 and a rigid printed circuit board 87. While a single printed circuit board is shown in these figures, alternative configurations are envisioned that could separate electrical components such as motor control sensors and microcontrollers, as well as MOSFETs (Metal-Oxide-Semiconductor Field-Effect Transistors), into two or more circuits, including two or more rigid circuit boards or a combination of rigid and flexible circuit boards. The board mount 86 may include a set of protrusions 88 shaped to align with a plurality of recesses 90 defined by the device housing 22. The set of protrusions 88 engages the set of recesses 90 to prevent movement of the board mount 86 relative to the device housing 22 in multiple degrees of freedom, such as at least two. Each protrusion 88 may also define a slot 92 to hold the position of a motor control sensor 32 relative to the board mount 86. The motor control sensor 32 may be inserted into the slot 92. One or more motor control sensors 32 may also be mounted on the surface of the printed circuit board 87 instead of in a slot in the board mount 86. The one or more motor control sensors may be implemented as analog Hall effect sensors.

[0132] In addition, refer to Figure 8 The board mount 86 can be secured to the device housing 22 using multiple mounting fasteners 96. The mounting fasteners 96 can extend through the board mount 86 and engage openings in the device housing 22 to secure the position of the printed circuit board assembly 33 in other degrees of freedom.

[0133] refer to Figure 10 The set of protrusions 88 can be positioned relative to each other in an arcuate arrangement. The set of protrusions 88 can engage the set of recesses 90 on the device housing 22, thereby preventing relative movement between the printed circuit board assembly 33 and the device housing 22 in multiple degrees of freedom.

[0134] refer to Figure 4 The printed circuit assembly 33 is further secured to its position within the device housing 22 by a plurality of mounting feet 94 located on the side of the rigid printed circuit board 87 opposite to the set of protrusions 88. The plurality of mounting feet 94 are positioned to engage the inner surface of the device housing 22 when the printed circuit board assembly 33 is inserted into the device housing 22.

[0135] The envisioned board mount arrangement offers several advantages. For example, by attaching the board mount to the printed circuit board including the motor control sensor, the position of the motor control sensor can be precisely controlled. Additionally, by engaging only one main side of the circuit board with the board mount, the circuit board can expand during thermal cycling without compromising the device's resilience. Furthermore, by engaging only the smaller side of the circuit board with the board mount, larger circuit boards offer additional flexibility, thus resisting breakage caused by torque during use with powered surgical tools.

[0136] As will be described in more detail below, the motor of handheld component 24 includes multiple magnets. Further references Figure 6-8 In conjunction with 10, the aforementioned set of notches 90 can define a series of notch peaks 97 and notch valleys 98, wherein when the handpiece 24 is inserted into the device housing 22, the innermost surface of the notch peak 97 is further away from the magnet of the handpiece's motor than the innermost surface of the notch valley 98. Thus, because the protrusion 88 of the plate mount 86 includes the motor control sensor 32, and because the protrusion 88 of the plate mount 86 is aligned with the notch valley 98, the motor control sensor 32 is closer to the magnet of the handpiece than in instances where the motor control sensor is aligned with the notch peak 97.

[0137] refer to Figure 4 The device housing 22 is formed to include a vent opening 100 for venting a void space. For example, the void space can be vented during sterilization. A cap 101 is attached to the device housing 22 to cover the vent opening 100. A pressure reducing valve 102 is at least partially inserted into the vent opening 100 to facilitate venting of the void space during sterilization. The cap 101 covers the pressure reducing valve 102 and can protect it, for example, from damage / impact from jets from the washer during washing. The pressure reducing valve 102 can be configured to open at a predetermined pressure. When the valve is open, a gap exists between the pressure reducing valve 102 and the cap 101. The cap 101 may include one or more slits located adjacent to or near the pressure reducing valve 102. The slits allow gas / air to be released.

[0138] Now for reference Figure 9-13 The battery and control module 21 includes at least three motor pins 48 spaced apart from each other to define an array of motor pins 48 that extends through the housing and extends out of a gap for establishing an electrical connection between the circuit board and the electric motor of the handheld device 24. It is conceivable that the battery and control module 21 includes at least six motor pins 48, with a plurality of motor pins 48 equidistantly positioned with respect to the center of the array. A hermetically sealed housing-terminal interface is defined by the device housing 22 and the at least three motor pins 48. The battery and control module 21 may also include a plurality of pin wires 104, such as at least three wires, wherein the wires 104 include wire terminals 106 connected to a first wire end of the at least three pin wires 104, and the other end of the pin wires 104 is connected to a rigid printed circuit board 87 via a suitable connection method (e.g., board wire terminals).

[0139] Each wire terminal 106 includes a first end portion 108 and a second end portion 110 opposite to the first end portion. The first end portion 108 is connected to one of the at least three wires 104, and the second end portion 110 is shaped to electrically engage one of the motor pins 48. More specifically, the first end portion 108 of the wire terminal 106 may define a plurality of arms 118, each arm 118 being crimped to engage the first wire end. The second end portion 110 of the wire terminal 106 may define a cylindrical gap 120, the cylindrical gap 120 being dimensioned to surround the motor pin 48. The second end portion 110 may be soldered to the motor pin 48.

[0140] The battery and control module 21 also includes a routing feature 112 disposed within a housing cavity and surrounding the at least three motor pins 48, defining a plurality of channels 114. The routing feature 112 may be integral with the device housing 22 or may be a separate component attached to the device housing 22. Each wire terminal 106 is positioned within one of the channels 114 of the routing feature 112. The plurality of channels 114 may include a first channel 114 and a second channel 114'. The plurality of channels 114 are used to fix the respective wire terminals 106 at different radial positions around the routing feature 112. The first channel 114 has a first depth, and the second channel 114' includes a second depth, the first depth being different from the second depth. This allows the pin wires 104 and their corresponding wire terminals 106 to be offset from each other, in this example, axially offset. The described embodiment provides a compact routing of the pin wires 104 in the axial direction, which contributes to a smaller device housing 22. Furthermore, this implementation ensures that the wires are laid out in a manner that minimizes stress on the wire bends, thereby maximizing the reliability of the battery and control module.

[0141] In some instances, the layout feature 112 includes an edge 116 circumferentially arranged around the layout feature 112 and surrounding the motor pin 48. The edge 116 may define the plurality of channels 114. In an example where the layout feature 112 includes the edge 116, a first end portion 108 of each wire terminal 106 is disposed outside the edge 116, and a second end portion 110 of the wire terminal 106 is disposed inside the edge 116. The wire terminal 106 defines a bend of at least 70 degrees, and wherein the first end portion 108 of the wire terminal 106 is separated from the second end portion 110 of the wire terminal 106 by the bend.

[0142] like Figure 9 As can be seen, at least one of the at least three motor pins 48 defines a longitudinal axis, and the circuit board 87 defines a longitudinal axis, wherein the longitudinal axis of the at least one motor pin 48 is parallel to the longitudinal axis of the circuit board 87.

[0143] refer to Figure 22 The image provides a cross-section of the powered surgical tool 20. It can be seen that the handpiece 24 is fully inserted into the battery and control module 21. The handpiece 24 includes a motor 122, such as a brushless motor. The handpiece 24 can be configured to generate a magnetic field. For example, the motor 122 may include a plurality of motor magnets 124 surrounding a motor shaft 126 or rotor. For example, the motor 122 may include a first rotor magnet 123 and a second rotor magnet 125 forming a pair of rotor magnets 123, 125. The first rotor magnet pair 123 and the second rotor magnet pair 125 can be configured to generate a magnetic field to cause rotation of the motor 122. The motor 122 includes a stacked element 128 or pile surrounding a portion of the motor magnets 124. A portion of the plurality of motor magnets 124 extends axially beyond the stacked element 128. The extension of the plurality of magnets beyond the stacked element 128 allows the magnetic field of the plurality of motor magnets 124 to be detected.

[0144] In other instances, motor 122 may include any suitable number of rotor magnets for forming any suitable number of corresponding rotor magnet pairs. For example, in an instance where motor 122 is a three-phase motor, motor 122 may include six rotor magnets forming three rotor magnet pairs. In such instances, these rotor magnets may be positioned anywhere along motor 122, such as being equidistant along motor 122. In an instance where motor 122 includes three rotor magnet pairs, these rotor magnet pairs may be arranged such that the first magnet of one rotor magnet pair is positioned at a 120-degree angle to the first magnet of every other rotor magnet pair.

[0145] The motor 122 may also include a handheld device circuit 130, which optionally includes a memory device and a data terminal that communicates with the handheld device circuit 130 and the memory device. The data terminal is configured to connect to a data pin 48' of the battery and control module 21 when the handheld device 24 is received in the recess 40. Thus, the data terminal 133 is in electrical communication with the memory device. The term memory device may be replaced by a microcontroller including onboard memory. Alternatively, the handheld device circuit may include a separate processor and a dedicated memory device communicating with that separate processor.

[0146] For reference Figure 5-6 As described in section 22, the battery and control module 21 may include one or more motor control sensors 32, which may define a set of motor control sensors 32. For example, as Figure 5-6 The motor control sensor 32 of the battery and control module 21 shown in Figure 22 can be one or more analog Hall effect sensors 32, which are connected to the control module controller 31 and configured to sense magnetic fields. Figure 22In this example, the battery and control module 21 includes first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3). The one or more motor control sensors 32 can be coupled to the printed circuit board assembly 33 by being mounted to the surface of a rigid printed circuit board 87, such as... Figure 5 As shown.

[0147] In addition, such as Figure 5-6 As shown in Figure 22, the battery and control module 21 may also include one or more wake-up sensors 134, which may define a set of wake-up sensors 134. This set of wake-up sensors 134 may be defined as at least three wake-up sensors 134. The one or more wake-up sensors 134 may be positioned distal to the motor control sensor 32 on the rigid printed circuit board 87 and may be fixed to the board mount 86 in a manner similar to that described with respect to the motor control sensor 32. Alternatively, the one or more wake-up sensors 134 may be directly mounted to the surface of the printed circuit board 87. When the handpiece 24 is inserted into the battery and control module 21, the set of three or more wake-up sensors may be positioned partially around the handpiece 24, such that the three or more wake-up sensors radially surround the plurality of motor magnets 124. This arrangement of the three or more wake-up sensors 134 provides improved accuracy because it takes into account the possibility that one or more of the wake-up sensors 134 may align with the gaps between the plurality of motor magnets. The three wake-up sensors 134 substantially guarantee that at least one of the wake-up sensors will detect a strong magnetic field, regardless of the rotation of the motor 122.

[0148] As will be described in more detail below, the battery and control module 21 can be configured to work with the handheld device 24 and the charging module 1100 (in... Figures 36-37 (as shown in the image) or programming fixture 1200 (in...) Figure 42 and 43 (shown in the diagram) connection. In such instances, when one of the handheld device 24, charging module 1100, or programming jig 1200 is connected to the battery and control module 21, the one or more wake-up sensors 134 may be positioned partially around components of the handheld device 24, charging module 1100, or programming jig 1200. This arrangement of the one or more wake-up sensors 134 ensures that the one or more wake-up sensors 134 sense the magnetic field generated by the rotor magnet pairs 123, 125 when the handheld device 24 is connected to the module housing 22, and sense the magnetic field generated by the charger module magnet M when the charging module 1100 is connected to the module housing 22. Figure 37 The magnetic field generated by the programming fixture 1200 (as shown) or sensed by the programming fixture magnet 1204 when the programming fixture 1200 is connected to the module housing 22. Figure 42 and43 The generated magnetic field (shown) provides improved accuracy. In one such example, when the handheld device 24 is connected to the battery and control module 21, the wake-up sensor 134 can be positioned around the plurality of motor magnets 124.

[0149] The set of motor control sensors 32 can be aligned with each other in a direction perpendicular to the axis of motor 122. Similarly, the set of wake-up sensors 134 can be aligned with each other in a direction perpendicular to the axis of motor 122. The set of wake-up sensors 134 can be arranged parallel to the set of motor control sensors 32.

[0150] The control module controller 31 may include any suitable number of motor control sensors 32 for sensing the magnetic field generated by the motor 122. As previously described, the motor 122 may include any suitable number of rotor magnets for forming any suitable number of corresponding rotor magnet pairs. For example, in an instance where the motor 122 is a three-phase motor, the motor 122 may include six rotor magnets forming three rotor magnet pairs. In such an instance, the control module controller 31 may include three motor control sensors 32 for sensing the magnetic field generated by each rotor magnet pair.

[0151] The control module controller 31 may include any suitable number of wake-up sensors 134. For example, the control module controller 31 may include a set of three or more wake-up sensors 134. The control module controller 31 may include any suitable number of wake-up sensors 134 to account for the possibility that one or more of the digital Hall effect sensors 134 are misaligned with the rotor magnet pairs 123, 125, the charger module magnet M, or the programming jig magnet 1204.

[0152] As will be described in more detail below, one or more wake-up sensors 134 may be configured to provide sensor signals indicating the presence of the handheld device 24, which is fully received in the battery and control module 21. Further reference Figure 22 Imagine that when the handheld component 24 is received in the recess 40, the wake-up sensor 134 is axially aligned with at least a portion of one of the plurality of motor magnets 124. More specifically, the one or more wake-up sensors 134 may be aligned with portions of the plurality of motor magnets 124 extending beyond the stacked element 128.

[0153] As will be explained in more detail below, the main controller 31 can be configured to regulate the power supplied to the battery and control module 21 for the one or more motor pins 48 based on sensor signals provided by the wake-up sensor 134. More specifically, the main controller 31 can supply power to the one or more motor pins 48 based on sensor signals provided by the wake-up sensor 134. In such an embodiment, the main controller 31 is configured to energize one or more motor terminals based on the output of the one or more wake-up sensors 134, and the main controller 31 is configured to commutate the motor 122 based on the one or more motor control sensors 32.

[0154] However, it is also envisioned that the wake-up sensor 134 can be omitted, and the main controller 31 can be configured to regulate the power supplied to the one or more motor pins 48 based on sensor signals provided by the motor control sensor 32. In this example, the main controller 31 will commutate the motor 122 based on the output of the motor control sensor 32, and wake up the battery and control module 21 based on the output of the motor control sensor 32.

[0155] The one or more wake-up sensors 134 can be implemented as digital Hall effect sensors, and the one or more motor control sensors 32 can be implemented as analog Hall effect sensors. In this document, the wake-up sensor 134 can be referred to as digital Hall effect sensor 134, and the motor control sensor 32 can be referred to as analog Hall effect sensor 32. Digital Hall effect sensors are ideal for wake-up functions because they have lower current consumption (less than 5 µA each) than analog Hall effect sensors (each greater than 5 mA). Analog Hall effect sensors are ideal for motor control functions because they have a higher acquisition rate than digital Hall effect sensors.

[0156] By adjusting the power, the main controller 31 can be configured to switch between a sleep state and an active state based on sensor signals from the wake-up sensor 134.

[0157] In sleep mode, the main controller 31 may cease performing certain functions, such as powering the motor 122 of the handheld device 24. In some embodiments, the controller 31 may also cease powering the motor control sensor 32 while in sleep mode. While in sleep mode, the main controller 31 may still consume some energy from the battery assembly 30 to maintain the ability to power the wake-up sensor 134. While in sleep mode, the main controller 31 may also still power one or more of the motor pins 48, specifically referred to as data pins 48'. Data pins 48' can be energized when the main controller 31 is in sleep mode. Data pins 48' can also be energized when in an active state. When the main controller 31 is in sleep mode, the powered surgical tool consumes less than 5 mA of current from the battery assembly 30.

[0158] As described above, in an alternative embodiment, the main controller 31 is configured to transition from a sleep state to an active state based on a sensor signal from a wake-up sensor in one embodiment.

[0159] A switching module 159, comprising multiple MOSFETs 159, can also be connected to the printed circuit board 87. While the invention envisions MOSFETs as switching components connected to the printed circuit board 87, other suitable transistors or switching components can be used. The switching module 159 can be used to control the operating direction of the motor of the handheld device 24, for example, forward or reverse direction.

[0160] Figure 14-21 Another embodiment of a powered surgical tool 220, shown in a pistol-like configuration, is depicted. The pistol-like battery and control module 221 includes a barrel 200 and a handle 201. The handle 201 extends downward from the barrel 200. A handpiece 224 can be inserted into a recess 240 in the barrel 200. Four battery cells 228 are disposed in the handle 201, these battery cells being surrounded by an insulating layer to form a battery assembly 230. The battery and control module 221 may have two spring-loaded triggers 202, 203, or switches. Both triggers 202, 203 extend forward from a distal portion of the handle 201. A medical practitioner can actuate the triggers 202, 203 to control the operation of the tool unit. The triggers 202, 203 may each include a magnet that is moved when the triggers 202, 203 are actuated by the user, as discussed in more detail below. The battery and control module 221 may include a pressure relief valve and a cap, which function substantially similarly to the pressure relief valve and cap discussed regarding the pencil-type configuration.

[0161] Similar to battery control module 21, battery and control module 221 includes at least one battery 28 in battery assembly 230, and a main controller 231 coupled to printed circuit board assembly 233, as will be discussed in more detail below. Main controller 231 communicates with battery 228 (which may be part of battery assembly 230), motor control sensor 232, and trigger sensor 235, and is also configured to communicate with handheld device 224 when it is detachably coupled to battery and control module 221. Main controller 231 may also communicate with memory device 295 on board assembly, and both may be positioned on first printed circuit board 249.

[0162] The main controller 231 can receive signals from the trigger sensor 235, and can draw power from at least one battery cell 228 to supply power to the motor of the handheld component 224. During operation, the main controller 231 is configured to determine the rotational position of the motor and control the motor based on the rotational position sensed by the one or more motor control sensors 232. The device housing 222 of the battery and control module 221 defines a recess 240 sized to detachably receive the handheld component 224. More specifically, the device housing 222 includes a front surface 242 defining an opening 244 that extends proximally to define the recess 240. The recess 240 may be at least substantially cylindrical to conform to the profile of the handheld component 224. Alternatively, the recess may be shaped in other ways, such as those described with respect to the battery and control module 421.

[0163] refer to Figure 15-1 8. The first printed circuit board 249, the second printed circuit board 251, and the fourth printed circuit board 255 can be disposed in the barrel body 200, while the third printed circuit board 253 is disposed in the handle 201. As shown in the figure, the first printed circuit board 249 is interconnected with the second printed circuit board 251 through a board connector 257, the first printed circuit board 249 is connected to the third printed circuit board 253 through a flexible circuit, and the first printed circuit board 249 is connected to the fourth printed circuit board 255 through a flexible circuit.

[0164] Multiple motor control sensors 232 can be coupled to the second printed circuit board 251. The motor control sensors 232 can be Hall effect sensors and can be similar to the previously described motor control sensor 32. A switching module 259 including multiple MOSFETs 270 can also be coupled to the second printed circuit board 251. Although this disclosure contemplates MOSFETs as switching components coupled to the second printed circuit board 251, other suitable transistors or switching components can be used. The switching module 259 can be used to control the operating direction of the motor of the handheld device 224, for example, forward or reverse direction.

[0165] The fourth printed circuit board 255 may include a plurality of motor pins 248. The plurality of motor pins 248 may be soldered to the fourth printed circuit board 255. One or more of the motor pins 248 may be connected to a switch module 259. The fourth printed circuit board 255 may also include one or more light sources 261, such as LEDs. The light sources 261 may be controlled by a main controller 231. The battery and control module 221 may include light guides 263 aligned with one or more light sources 261 on the third printed circuit board. The motor pins 248 may have a form factor other than pins and may be more generally referred to as motor terminals.

[0166] Trigger sensor 235 may be disposed on third printed circuit board 253. Trigger sensor 235 may be a Hall effect sensor and may be similar to the previously described manual switch sensor 34. Third printed circuit board 253 is disposed inside handle 201. In particular, third printed circuit board 253 is disposed close to triggers 202, 203 such that the plurality of trigger sensors 235 can sense the state of triggers 202, 203, for example, when triggers 202, 203 have been actuated by the user.

[0167] The first printed circuit board 249 and the second printed circuit board 251 can each be a rigid board, wherein the second printed circuit board 251 and the first printed circuit board 249 are arranged in a stacked configuration, and a plurality of motor control sensors 232 are connected to the second printed circuit board 251. A main controller 231 can be mounted to the second printed circuit board 251. The second printed circuit board 251 may also include a plurality of wake-up sensors 334, which function as described with respect to the battery and control module 21. The first printed circuit board 249 has a larger surface area than the second printed circuit board 251. When the handheld device 224 is connected to the battery and control module 221, the first printed circuit board 249 is also further away from the handheld device and the motor than the second printed circuit board 251.

[0168] refer to Figure 19 The device housing 222 may include one or more mounting posts 265 to position the fourth printed circuit board 255 within the device housing 222. The fourth printed circuit board 255 abuts against the mounting posts 256, such that the axial position of the fourth printed circuit board 255 is controlled within the battery and control module 221. The axial positioning of the fourth printed circuit board 255 is important because it includes multiple light sources, and these light sources need to be aligned with the light guide 263. The board mount 286 indirectly ensures the alignment of the fourth printed circuit board within the housing by locking all degrees of freedom of the first and second printed circuit boards. Fasteners engaging the fourth printed circuit board fix only one degree of freedom.

[0169] The device housing 222 may also include a plurality of support ribs 267, and the tool may also include a plate mount 286. The plate mount 286 may include a plurality of wings 269 for engaging the support ribs 267.

[0170] refer to Figure 16 and 17 The second printed circuit board 251 includes two main sides 271, wherein the board mount 286 contacts only one of the two main sides 271. The second printed circuit board 251 includes at least four secondary sides 273, wherein the board mount 286 contacts two or fewer secondary sides 273. In some configurations, the second printed circuit board 251 includes at least four secondary sides 273, wherein the board mount 286 does not contact the secondary sides 273. This configuration may be advantageous because the printed circuit board 87 can expand laterally when exposed to elevated temperatures without being constrained by the board mount.

[0171] The board mount 286 includes a body portion 275 and a flange 277 defining a hole for inserting a fastener. The flange 277 extends vertically from the body portion 275. The flange 277 is configured to partially secure the position of a fourth printed circuit board 255. The flange 277, together with the mounting post 265, secures the position of the fourth printed circuit board 255.

[0172] The battery and control module 221 also includes a plurality of spacers 279 disposed between a first printed circuit board 249 and a second printed circuit board 251. Each of the plurality of spacers 279 defines an aperture, and a plurality of board fasteners 281 are arranged to extend through the second printed circuit board 251, an aperture of at least one of the plurality of spacers 279, and the first printed circuit board 249. A board mounting base 286 may define a plurality of mounting holes, each of the plurality of mounting holes including a threaded insert 283.

[0173] Similar to battery and control module 21, battery and control module 221 may include a set of protrusions 288, and the device housing defines a set of recesses 290, wherein the set of protrusions 288 engages the set of recesses 290 to prevent the plate mount 286 from moving relative to the device housing 222 in multiple degrees of freedom. The set of recesses 290 and / or the set of protrusions 288 are positioned relative to each other in an arcuate arrangement. Each of the set of protrusions 288 defines a slot 292 for securing one of the plurality of motor control sensors 232. As described above with respect to recess 90, recess 290 defines a series of recess peaks 297 and recess valleys 298, wherein the innermost surface of the recess peak 297 is further away from the magnet of the motor than the innermost surface of the recess valley 298.

[0174] The first printed circuit board 249 may be longer and wider than the second printed circuit board 251, and therefore have a larger surface area. For example, the surface area of ​​the first printed circuit board 249 may be at least 30, 40, or 50% larger than that of the second printed circuit board 251. The first printed circuit board 249 and the second printed circuit board 251 are arranged in a stacked configuration, which helps to minimize the footprint of the power surgical tool 220, particularly reducing the footprint of the battery and control module. The first printed circuit board 249 may have a first longitudinal axis, and the second printed circuit board 251 may have a second longitudinal axis, wherein the first and second longitudinal axes are aligned. The first printed circuit board 249 and the second printed circuit board 251 may each have a rigid back layer and are therefore rigid printed circuit boards.

[0175] Because the first printed circuit board 249 is longer than the second printed circuit board 251, the distal end of the first printed circuit board 249 extends beyond the distal end of the second printed circuit board 251. Furthermore, the second printed circuit board 251 can be positioned so that it does not extend beyond the first printed circuit board 249 in any direction, except as described above, by being spaced apart from the first circuit board.

[0176] Figure 23-25 Another embodiment of a powered surgical tool 420, shown in a pistol-style configuration with a top opening, is depicted. The pistol-style battery and control module 421 includes a receiver surface 404 and a handle 401. The handle 401 extends downward from the receiver surface 404. A handpiece 424 can be inserted into the receiver surface 404. The battery and control module 421 may include any features described with respect to battery and control modules 21 and 221. However, the top-opening configuration of the battery and control module 421 relative to the handpiece 424 provides certain ergonomic and construction advantages.

[0177] See Figure 25 and 26 The handheld component 424 may include a guide rail 405, and the receiver surface 404 of the battery and control module 421 defines a slot 406. The guide rail 405 and slot 406 are configured such that the guide rail is slidable within the slot 406 to allow engagement between the handheld component 424 and the battery and control module 421. An opposite arrangement of the slot defined by the handheld component and the guide rail defined by the battery and control module is also contemplated, as are other arrangements besides the slot-rail arrangement. The battery and control module 421 may also include a latch assembly with a locking member, constructed similarly to that described above with respect to the battery and control module 21. Similar to the handheld component 24, the handheld component 424 may include the receiver surface 404.

[0178] As described above regarding battery and control module 21, battery and control module 421 may be characterized by a device housing 422 defining a recessed space that receives a rechargeable battery module disposed therein. Battery and control module 21 may also include a printed circuit board including a controller configured to regulate the power drawn from the rechargeable battery module based on user input. The printed circuit board may also include a motor sensor configured to output a motor sensor signal indicating the state of the motor of handheld device 424.

[0179] The battery and control module 421 may also include a motor pin 448 extending through the device housing for establishing an electrical connection between the printed circuit board and the motor of the handheld component 424. As described above, the motor pin 448 may employ other form factors, such as other shapes of electrical terminals. The battery and control module 421 may include a safety vent as described above with respect to battery and control module 21. The battery and control module 421 may also include one or more motor control sensors as described above with respect to battery and control module 221, which may be implemented as Hall effect sensors.

[0180] As will be described in more detail below, the handpiece 424 may take the form of a pin or wire driver defining a sleeve 408. This sleeve 408 allows a retaining pin and retaining wire to pass through the proximal end of the handpiece 424, extend through the body of the handpiece, and protrude through the distal end of the handpiece. The handpiece 424 may include features of U.S. Patent Publication No. 20210220035, the entire contents of which are incorporated herein by reference. The battery and control module 421 may be without a sleeve, allowing the wire or pin to enter the proximal end of the handpiece 424. The proximal end of the battery and control module 421 may be shaped to allow the wire or pin to enter the handpiece 424 from the proximal end of the tool 420. For example, the control module 421 may define a groove 410 to receive the wire or pin when it enters the proximal end of the handpiece 424. Because the battery and control module is without a sleeve, the battery and control module 421 may define such a sleeve without additional soldering locations in the device housing 422. Avoiding these additional soldering locations simplifies the design of the battery and control module 421 and eliminates the possibility of sterilizing agents entering during the sterilization process.

[0181] See Figure 24The powered surgical tool 420 can be configured such that the distal end face 411 of the handpiece 424 is exposed when it is connected to the battery and control module 421. Additionally, a portion of the proximal end face 412 of the handpiece 424 is exposed when it is connected to the battery and control module 421. Because the distal and / or proximal end faces of the handpiece 424 are exposed, the battery and control module 421 can be relatively small, as it no longer has the plastic features that surround the handle 424 in a circumferential arrangement. Furthermore, by using slots and guide rails to connect the handpiece 424 to the battery and control module 421, the battery and control module 421 no longer has the cylindrical profile features that would result in a relatively large device. This, in turn, allows for an increase in the diameter of the motor, without being too large for the user. The increased diameter allows for a reduction in the length of the motor, thereby reducing the size of the tool.

[0182] refer to Figure 26-29 The handheld device 424 is characterized by a motor 522 having a motor magnet 524 and a motor shaft 526. The motor 522 may include a laminated element 228 surrounding the motor shaft 526. The handheld device 424 may also include handheld device circuitry 530, such as a rigid circuit board, which includes a handheld device memory 532 and conductive terminals for receiving motor pins, one of which is a data terminal 533. The motor shaft 526 may define a sleeve 536. The handheld device 424 may also include a gearbox 538 for changing output parameters of the motor shaft output to the tool connector, such as the speed, torque, or direction of the output to the tool connector. The surgical handheld device 424 may define an axis, and the sleeve 536 may surround this axis.

[0183] refer to Figure 29 The motor shaft 526 or rotor may define an axis. A rigid circuit board 530 may be defined as a rigid circuit board including a controller. The rigid circuit board 530 may be oriented perpendicular to the rotor axis. The rigid circuit board 530 may also be sleeved via a sleeve aperture 540. The sleeve aperture 540 may be coaxial with the sleeve 536, and multiple terminals including data terminals 533 may be soldered to the rigid circuit board and may be shaped to engage motor pins 448 when the handpiece 424 is connected to the battery and control module 421. This arrangement of the rigid circuit board 530 can result in a relatively short handpiece 424, which allows the tool 420 to be relatively shorter and more compact than a design where the circuit board is oriented parallel to the motor shaft axis.

[0184] refer to Figure 30 and 31The document describes an alternative handheld device 624. The handheld device 624 is characterized by a motor 722 having a motor magnet 724 and a motor shaft 726. The motor 722 may include a laminated element 728 surrounding the motor shaft 726. The handheld device 624 may also include a handheld device circuit 730, which includes a handheld device memory 732 and conductive terminals for receiving motor pins, one of which is a data terminal 733. Other motor pins may be used as power terminals and may operate at higher voltages than the data terminals. The handheld device 624 may also include a gearbox 738 for changing output parameters of the motor shaft output to the tool connector, such as the speed, torque, or direction of the output to the tool connector.

[0185] The handheld circuitry 730 can be defined as a rigid circuit board including a controller. The controller may be integrated with a memory device 732 and is not shown separately. The handheld circuitry 730 may be oriented perpendicular to the axis of the motor shaft 726. The plurality of terminals, including data terminals 733, can be soldered to the rigid circuit board and can be shaped to engage motor pins 248 when the handheld device 624 is connected to the battery and control module 221. This arrangement of the handheld circuitry 730 allows for a relatively shorter handheld device 624, which allows for a relatively shorter and more compact tool 220. The handheld device can also be connected to other control modules, such as control module 21 or control module 421.

[0186] refer to Figure 32 and 33 The document describes an alternative handheld device 824. The handheld device 824 is characterized by a motor 822 having a motor magnet 924 and a motor shaft 926. The motor 922 may include a laminated element 928 surrounding the motor shaft 926. The handheld device 824 may also include a handheld device circuit 930, which includes a handheld device memory 932 and conductive terminals for receiving motor pins, one of which is a data terminal 933. The handheld device 824 may also include a gearbox 938 for changing output parameters of the motor shaft output to the tool connector 826, such as the speed, torque, or direction of the output to the tool connector 826.

[0187] The handheld circuitry 930 may be defined as a flexible-rigid board comprising a flexible portion 942 and a rigid portion 944. The rigid portion 944 may be oriented parallel to the axis of the motor shaft 926. The plurality of terminals, including data terminals 933, may be soldered to the flexible portion 942 and may be shaped to engage motor pins 248 when the handheld device 824 is coupled to the battery and control module 221. This particular arrangement of the rigid and flexible portions advantageously provides a compact design while also providing space for electrical components in the handheld device, including, but not limited to, the controller and memory devices of the handheld device. The controller and memory devices may be integrated into a single unit. In any instance, these electrical components may be located on the rigid portion of a circuit board. It is also contemplated that the handheld device may be configured to operate in conjunction with the battery and control module 421, as with all handheld devices described in this disclosure.

[0188] Pin 48 of the battery and control module 21 can establish an electrical connection between the control module controller 31 and the device connected to the battery and control module 21. Figure 34 and 35 Two examples of pin 48 are shown in the figure.

[0189] Figure 34 A first example of a pin 48 for establishing an electrical connection between a control module controller 31 and a device connected to the battery and control module 21 is shown. As shown, pin 48 includes a first end 1050 and a second end 1052. Either the first end 1050 or the second end 1052 can be configured to be electrically connected to the control module controller 31, and either the first end 1050 or the second end 1052 can be configured to be electrically connected to electrical components of a device (such as a handheld device 24) connected to the battery and control module 21. Additionally, because... Figure 34 The pin 48 is geometrically symmetrical, so that when the pin 48 is injection molded into the module housing 22 of the battery and control module 21, the pin 48 cannot be incorrectly loaded into the injection mold. Furthermore, the pin 48 includes abutments 1054 defining grooves 1056. These abutments 1054 interact with the module housing 22 to provide a seal configured to prevent vapor and liquid ingress into the battery and control module 21. During the injection molding process of the pin 48 into the module housing 22, plastic flows into the grooves 1056 to attach the pin 48 to the module housing 22. These abutments 1054 are also configured to facilitate securing the pin 48 to the battery and control module 21 once the pin 48 is injection molded into the battery and control module 21.

[0190] Figure 35A second example of a pin 48 for establishing an electrical connection between a control module controller 31 and a device coupled to the battery and control module 21 is shown. As shown, pin 48 includes a first end 1058 and a second end 1060. The first end 1058 can be configured to be electrically connected to the control module controller 31, and the second end 1060 can be configured to be electrically connected to electrical components of a device coupled to the battery and control module 21 (such as a handheld device 24). Additionally, pin 48 includes a semi-groove 1062 defined by an abutment portion 1064. The semi-groove 1062 is configured to receive an O-ring such that the O-ring is proximal to the abutment portion 1064. The O-ring is configured to be sandwiched between the abutment portion 1064 and the module housing 22 of the battery and control module 21 to provide a seal configured to prevent vapor and liquid ingress into the battery and control module 21. In addition, pin 48 includes barbs 1065, which are configured to help secure pin 48 to the battery and control module 21 while providing a seal configured to prevent vapor and liquid from entering the battery and control module 21.

[0191] Various aspects of powered surgical tools, including aspects of the surgical handpiece and aspects of the battery and control module, are described in PCT / IB2022 / 057637, the entire contents of which are incorporated herein by reference. Therefore, any described feature of the battery and control module or surgical handpiece described herein is expressly contemplated in conjunction with one or more features described in this application.

[0192] The module housing 22 of the battery and control module 21 can be configured to be received by the charging module 1100. Figure 36 In one example, the charging module 1100 includes a charging adapter 1102, and the module housing 22 of the battery and control module 21 is connected to the charging module 1100 via the charging adapter 1102. Figure 36 As shown, the recess 40 of the module housing 22 receives the charging adapter 1102, and as indicated by the dashed arrow, the rechargeable battery module 28 receives charging power from the charging module 1100.

[0193] Charging module 1100 Figure 37 This is further illustrated in the text. For example... Figure 37 As shown, the charging module 1100 may include a recess 1104. The charging module 1100 may be configured to provide charging power to a device received by the recess 1104. For example, a rechargeable battery may be received by the recess 1104, and the rechargeable battery may be configured to receive charging power from the charging module 1100 in response to contact with the charging module 1100. The charging module 1100 may include any suitable number of recesses 1104 arranged in any suitable manner. For example, in Figure 37In the charging module 1100, there are six recesses 1104. The six recesses 1104 are arranged in a two-row, three-column configuration, wherein each row includes three recesses 1104 arranged along the direction of the first charger axis AX1, and wherein each column includes two recesses 1104 arranged along the direction of the second charger axis AX2 perpendicular to the first charger axis AX1.

[0194] The charging adapter 1102 is configured to change the form factor of the charging module 1100. For example, the charging adapter 1102 is configured to be received by the charging module 1100 and to engage with a device not formed to be received by the recess 1104, thereby allowing the charging module 1100 to provide charging power to such a device. See, for example, [link to documentation]. Figure 36 The powered surgical tool 20 is not shaped to be received by the recess 1104. The charging adapter 1102 is configured to be received by the charging module 1100 and connected to the module housing 22, such that the charging module 1100 can provide charging power to the rechargeable battery module 28 of the powered surgical tool 20 via the charging adapter 1102. Specifically, as... Figure 37 As shown, the charging adapter 1102 includes a charger protrusion 1108 configured to be received by a recess 1104 of the charging module 1100 and a module protrusion 1110 configured to be received by a module housing 22 of the battery and control module 21. The module protrusion 1110 is received by the module housing 22 to allow the charging module 1100 to provide power to the rechargeable battery module 28 via the charging adapter 1102.

[0195] Additionally, the charging adapter 1102 alters the shape factor of the charging module 1100, causing the device connected to the charging adapter 1102 to extend along the direction of the module protrusion 1110. For example, as Figure 37 As shown, the recess 1104 includes a surface 1106 facing the surface direction D1. In an example where the charging adapter 1102 is not received by the charging module 1100, the device received by the recess 1104 of the charging module 1100 extends along the surface direction D1. Figure 37 As shown, the module protrusion 1110 extends along a protrusion direction D2, which is different from the surface direction D1. In an example where the charging adapter 1102 is received by the charging module 1100, the device connected to the charging adapter 1102 via the module protrusion 1110 extends along the protrusion direction D2. Thus, in an example where multiple devices are connected to the charging adapter 1102 via the module protrusion 1110, the multiple devices can be aligned for easy access by the user.

[0196] The charging adapter 1102 can be configured to connect with any embodiment of the powered surgical tool described herein. For example, Figure 36The charging adapter 1102 is connected to both the pencil-grip type powered surgical tool (surgical tool 20) and the pistol-grip type powered surgical tool (surgical tool 220). Specifically, the charging adapter 1102 is configured to connect to the module housing 22 of the battery and control module 21 and the module housing 222 of the battery and control module 221. In each embodiment, the module housings 22, 222 of the respective battery and control modules 21, 221 are connected to the charging module 1100 via the charging adapter 1102, and the respective rechargeable battery modules 28, 228 receive charging power from the charging module 1100. In other instances, the charging module 1100 may be configured to connect to any other embodiment of the powered surgical tool (such as powered surgical tool 420).

[0197] The charging adapter 1102 may include components that allow the charging adapter 1102 to be coupled to various embodiments of powered surgical tools. See also Figure 38 The module protrusion 1110 may include a first portion 1112 shaped to be received by the module housing 22 of the powered surgical tool 20, and a second portion 1114 shaped to be received by the module housing 222 of the powered surgical tool 220. See also Figure 36 The first portion 1112 is shown as a module housing 22 receiving the powered surgical tool 20, and the second portion 1114 is shown as a module housing 222 receiving the powered surgical tool 220. The recess 40 of the module housing 22 (as shown) Figure 1 (As shown) may include a first radius, and the recess 240 of the module housing 222 (as shown) Figure 15 (As shown) may include a second radius different from the first radius. The first portion 1112 may include a cylindrical shape sized to be received by the recess 40 of the module housing 22, and the second portion 1114 may include a cylindrical shape sized to be received by the recess 240 of the module housing 222.

[0198] The charging adapter 1102 may also include components for ensuring that the module protrusion 1110 is properly received by the powered surgical tool in various embodiments.

[0199] refer to Figure 38The charging adapter 1102 may include alignment features 1116 and 1116', whereby alignment feature 1116 is configured to ensure that module protrusion 1110 is properly received by module housing 22, and alignment feature 1116' is configured to ensure that protrusion 1104 is properly received by module housing 222. During the reception of module protrusion 1110 by module housings 22, 222, the corresponding alignment features 1116, 1116' are configured to engage module housings 22, 222 before pins 48, 248 of the battery and control modules 21, 221 are electrically connected to the charging adapter 1102. In this way, alignment features 1116, 1116' protect pins 48 by ensuring that pins 48 of the battery and control module 21 are received by pin slots 1112 of the charging adapter 1102. Additionally, alignment features 1116, 1116' may be configured to prevent rotation of module housings 22, 222 after receiving module protrusion 1110. Alternatively, the charging adapter 1102 may include additional features configured to prevent the module housing 22, 222 from rotating after receiving the module protrusion 1110.

[0200] The charging adapter 1102 may also include a latch L1 configured to engage an interface with the module housing 22 of the powered surgical tool 20 to ensure that the module protrusion 1110 is secured to the module housing 22 after the module housing 22 receives the module protrusion 1110. The charging adapter 1102 may also include a latch L2 configured to engage an interface with the module housing 222 of the powered surgical tool 220 to ensure that the module protrusion 1110 is secured to the module housing 222 after the module housing 222 receives the module protrusion 1110.

[0201] The charging adapter 1102 can be configured to generate a magnetic field. For example, in Figure 38 In one example, the charging adapter 1102 includes a magnet M disposed on a module protrusion 1110, which is configured to generate a magnetic field. Figure 38 In this example, the magnet M is located near (or close to) the latch L1. However, in other examples, the magnet M can be positioned at any other suitable location on the charging adapter 1102 or the charging module 1100. Figure 41As shown, the wake-up sensor 134 of the battery and control module 21 can be configured to sense a magnetic field generated by the magnet M in response to the module housing 22 receiving the module protrusion 1110; and the wake-up sensor 334 of the battery and control module 221 can be configured to sense a magnetic field generated by the magnet M in response to the module housing 222 receiving the module protrusion 1110. The controllers 31 and 231 can be configured to transition from a sleep state to an active state based on the wake-up sensors 134 and 334 sensing the magnetic field generated by the magnet M, wherein the controllers 31 and 231 are configured to communicate with the charger when the controllers are in an active state.

[0202] refer to Figure 39 Each charger protrusion 1108 of the charging adapter 1102 may include an adapter contact 1119. For example... Figure 40 As shown, the adapter contact 1119 includes an adapter ground contact 1120, an adapter communication contact 1122, and an adapter power contact 1124. Each recess 1104 of the charging module 1100 may include a charger ground terminal 1126, a charger communication terminal 1128, and a charger power terminal 1130, as shown. Figure 41 As shown. When the charger protrusion 1108 is received by the recess 1104, the adapter ground contact 1120 contacts the charger ground terminal 1126, the adapter communication contact 1112 contacts the charger communication terminal 1128, and the adapter power contact 1124 contacts the charger power terminal 1130.

[0203] refer to Figure 41 Each module protrusion 1110 of the charging adapter 1102 includes an adapter terminal 1121. Specifically, the adapter terminal 1121 includes an adapter ground terminal 1132, a first adapter communication terminal 1134, a second adapter communication terminal 1136, and an adapter power terminal 1138. When the module protrusion 1110 of the charging adapter 1102 is received by the module housings 22, 222 of the battery and control modules 21, 221, the adapter terminal 1121 contacts pins 48, 48', enabling the charging adapter 1102 to facilitate communication between the charging module 1100 and the battery and control modules 21, 221, and enabling the charging module 1100 to provide charging power to the rechargeable batteries of the battery and control modules 21, 221.

[0204] It should be noted that although the module housings 22, 222 of the battery and control modules 21, 221 are shown as receiving... Figure 37In one example, the charging adapter 1102 has a module protrusion 1100; however, in other examples, the charging adapter 1102 may alternatively be configured to receive components of the battery and control modules 21, 221. For example, the charging adapter 1102 may define a recess sized to removably receive the module housings 22, 222 of the battery and control modules 21, 221.

[0205] The charging adapter 1102 and its components may include any suitable structure and any suitable size. (Reference) Figure 37 The charging adapter 1102 includes two charger protrusions 1108 arranged along the direction of the first charger axis AX1, such that when the charging adapter 1102 is received by the charging module 1100, the charging adapter 1102 is received by two recesses 1104 of the charging module 1100 and occupies a single row of recesses 1104. Additionally, the charging adapter 1102 may include two module protrusions 1110 arranged along the direction of the second charger axis AX2. Each module protrusion 1110 may include a width w along the second charger axis AX2. a This makes the width w a The sum is less than the width w of the groove 1104 along the second charger axis AX2. c Thus, when the charging adapter 1102 is received by the two recesses 1104 of the charging module 1100 and occupies a single row of recesses 1104, the charging module 1100 is able to provide charging power to two powered surgical tools connected to the module protrusion 1110 of the charging adapter 1102. In this way, the charging adapter 1102 retains the ability of the charging module 1100 to provide charging power to multiple devices corresponding to the multiple recesses 1104.

[0206] The charging adapter 1102 may include any suitable number of charger protrusions 1108 and module protrusions 1110. For example, in Figure 37 In the charging adapter 1102, there are a first charger protrusion 1108(1) and a second charger protrusion 1108(2), as well as a first module protrusion 1110(1) and a second module protrusion 1110(2). The first charger protrusion 1108(1) and the second charger protrusion 1108(2) are configured to be received by a first recess 1104(1) and a second recess 1104(2) of the charging module 1100, such as Figure 37 As indicated by the arrows in the diagram. Each of the first module protrusion 1110(1) and the second module protrusion 1110(2) can be received by the module housing 22 of the battery and control module 21. For example, in Figure 36 In the diagram, module protrusion 1110 is shown as being received by module housings 22, 222 of battery and control modules 21, 221.

[0207] The charging module 1100 can accept any suitable number of charging adapters 1102. For example, Figure 36 and 37 The charging module 1100 includes six recesses 1104 arranged in a 2x3 grid, and each charging adapter 1102 includes two charger protrusions 1108 configured to be received by the two recesses 1104 along the direction of the first charger axis AX1. As described below, Figure 36 and 37 The charging module 1100 is configured to receive three charging modules 1102(1), 1102(2), and 1102(3). In other instances, the charging module 1100 may include recesses 1104 in different arrangements or in different numbers.

[0208] The module housing 22 of the battery and control module 21 can be configured to be with Figure 42 and 43 The programming jig 1200 shown is connected. For example, a recess 40 in the module housing 22 can receive the programming jig 1200. Once the module housing 22 of the battery and control module 21 receives the programming jig 1200, the computing system connected to the programming jig 1200 can update the control module controller 31 of the battery and control module 21, repair the control module controller 31 of the battery and control module 21, or run diagnostics on it.

[0209] The programming fixture 1200 can be configured to connect to the battery and control module 21 in any implementation. For example, the module housing 222 of the battery and control module 221 can also be configured to connect to the programming fixture 1200.

[0210] Additionally, although the module housing 22 of the battery and control module 21 is configured to be in Figure 42 and 43 In one instance, the programming fixture 1200 is received; however, in other instances, the programming fixture 1200 may be configured to receive components of the battery and control module 21. For example, the programming fixture 1200 may define a recess sized to removably receive the module housing 22 of the battery and control module 21.

[0211] The various features of the programming fixture 1200 Figure 42 and 43 As shown in [the image]. Figure 42 and 43In this example, the programming fixture 1200 includes alignment features 1202 and 1202', whereby alignment feature 1202 is configured to ensure that the programming fixture 1200 is correctly received by the battery and control module 21, and alignment feature 1202' is configured to ensure that the programming fixture 1200 is correctly received by the battery and control module 221. Additionally, alignment features 1202 and 1202' can be configured to prevent rotation of the battery and control module 21 after receiving the programming fixture 1200. When the module housings 22 and 222 receive the programming fixture 1200, alignment features 1202 and 1202' are configured to engage the module housings 22 and 222 before the pins 48 of the battery and control module 21 are electrically connected to the programming fixture 1200. In this way, alignment features 1202 and 1202' protect pins 48 by ensuring that pins 48 of the battery and control module 21 are received by the pin slots 1206 of the programming fixture 1200.

[0212] The programming fixture 1200 can be configured to generate a magnetic field. For example, in Figure 42 and 43 In one example, the programming fixture 1200 includes a magnet 1204 configured to generate a magnetic field. The magnet 1204 can be located at any suitable position on the programming fixture 1200.

[0213] Figure 44 A system 10 for identifying devices connected to a powered surgical tool 20 is shown. As shown, the powered surgical tool 20 includes a battery and a control module 21. Additionally, the battery and control module 21 includes components configured to connect with a handheld device 24. Figure 2 (as shown), charging module 1100 ( Figure 36 (as shown) and programming fixture 1200 ( Figure 42 and 43 The module housing 22 (as shown) is connected. Figure 44 As shown, the handheld device 100 includes a motor 122, which includes a first rotor magnet 123 and a second rotor magnet 125 forming a pair of rotor magnets 123, 125. The charging module 1100 includes a magnet M, and the programming jig 1200 includes a magnet 1204. The battery and control module 21 includes a control module controller 31, which is configured to determine whether the module housing 22 is connected to the handheld device 24, the charging module 1100, or the programming jig 1200 based on sensing the magnetic field generated by the rotor magnet pair 123, 125, the charging module magnet M, or the programming jig magnet 1204.

[0214] It should be noted that, although Figure 44 System 10 is shown as including a battery and control module 21, but system 10 may include a battery and control module of any embodiment described herein. For example, system 10 may include Figure 1-13The pencil grip type configuration includes a battery and control module 21. Figure 14-23 The battery and control modules 221 and 421 are configured with a pistol grip type for 23-35 pistols. As described below, Figure 1-13 The pencil grip type configuration includes a battery and control module 21. Figure 14-23 The battery and control modules 221 and 421 of the pistol grip configuration for 23-35 can be connected to the handheld component 24, the charging module 1100, or the programming fixture 1200.

[0215] The control module controller 31 can sense the magnetic field generated near the battery and control module 21. Figure 5-6 The analog Hall effect sensor 32 shown in Figure 22 can be configured to sense the magnetic field generated by the rotor magnet pairs 123, 125 of the motor 122. The analog Hall effect sensor 32 can also be configured to sense the magnetic field generated by the charging adapter 1102 (…). Figure 37 The magnet M shown) and the magnet 1204 of the programming fixture 1200. Figure 42 and 43 The magnetic field generated (as shown). The simulated Hall effect sensor 32 can sense the magnetic field generated by the rotor magnet pairs 123 and 125 when the handheld device 24 is connected to the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is connected to the module housing 22, or the magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is connected to the module housing 22.

[0216] The control module controller 31 may also include one or more digital Hall effect sensors 134, such as in Figure 5-6 As shown in Figure 22, the sensor is coupled to the control module controller 31 and configured to sense magnetic fields. The digital Hall effect sensor 134 can be coupled to the printed circuit board assembly 33 by being mounted to the surface of a rigid printed circuit board 87, such as... Figure 5 As shown. The digital Hall effect sensor 134 can be configured to sense the magnetic field generated by the rotor magnet pairs 123, 125 of the motor 122. The digital Hall effect sensor 134 can also be configured to sense the magnetic field generated by the charging adapter 1102 ( Figure 37 The magnet M shown) and the magnet 1204 of the programming fixture 1200. Figure 42 and 43 The magnetic field generated (as shown in the figure).

[0217] The digital Hall effect sensor 134 can sense the magnetic field generated by the rotor magnet pairs 123 and 125 when the handheld device 24 is connected to the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is connected to the module housing 22, or the magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is connected to the module housing 22.

[0218] As previously described, the control module controller 31 is configured to determine whether the module housing 22 is connected to the handheld device 24, the charging module 1100, or the programming fixture 1200 based on the magnetic field sensed by the digital Hall effect sensor 134 from the rotor magnet pairs 123, 125, the charger module magnet M, or the programming fixture magnet 1204. However, before determining whether the module housing 22 is connected to the handheld device 24, the charging module 1100, or the programming fixture 1200, the control module controller 31 is configured to operate in a sleep state and transition from the sleep state to an active state.

[0219] It should be noted that the main controller 231 of the battery and control module 221 can be similarly configured to determine whether the module housing 222 is connected to the handheld device 24, the charging module 1100, or the programming fixture 1200 based on the magnetic field generated by the rotor magnet pairs 123, 125, the charger module magnet M, or the programming fixture magnet 1204, sensed by the digital Hall effect sensor 334. The description of the main controller 31 herein should be understood to apply to the main controller 231.

[0220] refer to Figure 45 In sleep mode, the digital Hall effect sensor 134 is activated, while the analog Hall effect sensor 32 is deactivated. In other words, during sleep mode, the digital Hall effect sensor 134 is configured to sense magnetic fields, such as those generated by the rotor magnet pairs 123, 125, the charger module magnet M, or the programming jig magnet 1204, while the analog Hall effect sensor 32 cannot sense magnetic fields. In sleep mode, the digital Hall effect sensor 134 is configured to receive power from the rechargeable battery module 28, while the analog Hall effect sensor 32 does not receive power from the rechargeable battery module 28.

[0221] like Figure 45 As shown, once the digital Hall effect sensor 134 senses a magnetic field, the control module controller 31 switches to an active state. For example, the digital Hall effect sensor 134 can sense the magnetic field generated by the rotor magnets 123, 125 when the handheld device 24 is connected to the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is connected to the module housing 22, or the magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is connected to the module housing 22. Therefore, once one of the handheld device 24, the charging module 1100, or the programming fixture 1200 is connected to the module housing 22, the control module controller 31 switches to an active state.

[0222] In the active state, the analog Hall effect sensor 32 is configured to sense magnetic fields and receive power from the rechargeable battery module 28. In some instances, the digital Hall effect sensor 134 is inactive during the active state and does not receive power from the rechargeable battery module 28. In alternative instances, the digital Hall effect sensor 134 is also active during the active state and receives power from the rechargeable battery module 28.

[0223] In this way, the digital Hall effect sensor 134 is used as a wake-up sensor. In some instances, the analog Hall effect sensor 32 receives a greater amount of power from the rechargeable battery module 28 in the active state compared to the power received by the digital Hall effect sensor 134 in the sleep state. Advantageously, since the analog Hall effect sensor 32 is not activated and does not receive power during the sleep state, the power supplied to sensors 134, 32 is saved. Furthermore, by detecting the presence of a magnetic field using the digital Hall effect sensor 134 instead of the analog Hall effect sensor 32, the control module controller 31 is able to detect whether the handheld device 24, the charging module 1100, or the programming jig 1200 is connected to the battery and control module 21, while minimizing the power supplied by the rechargeable battery module 28. The digital Hall effect sensor 134 is ideal for detecting magnetic fields during the sleep state because it has a lower current consumption (less than 5 μA each) than the analog Hall effect sensors (each greater than 5 mA). Additionally, the analog Hall effect sensors are ideal for motor control functions because they have a higher acquisition rate than the digital Hall effect sensors.

[0224] During the active state, one of the handheld device 24, the charging module 1100, or the programming jig 1200 is connected to the module housing 22. The control module controller 31 can then be configured to determine whether the module housing 22 is connected to the handheld device 24, the charging module 1100, or the programming jig 1200 based on sensing the magnetic field generated by the rotor magnet pairs 123, 125, the charger module magnet M, or the programming jig magnet 1204. The control module controller 31 can determine whether the module housing 22 is connected to the handheld device 24, the charging module 1100, or the programming jig 1200 based on sensing readings SR1, SR2, SR3 provided by first, second, and third analog Hall effect sensors 32(1), 32(2), 32(3), wherein the sensing readings SR1, SR2, SR3 correspond to the magnitude (or intensity) of the magnetic field sensed by the first, second, and third analog Hall effect sensors 32(1), 32(2), 32(3).

[0225] Figure 46Example sensing readings SR1, SR2, and SR3 provided by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) are shown when the control module controller 31 is in sleep mode. As shown, the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) only provide the bias voltage for the battery and control module 21 because the handheld device 24, charging module 1100, or programming jig 1200 is not connected to the module housing 22, and the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) do not sense the magnetic field generated by the handheld device 24, charging module 1100, or programming jig 1200.

[0226] Figure 47 Example sensing readings SR1, SR2, and SR3 provided by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) are shown when the control module controller 31 is active and when the handheld device 24 is connected to the module housing 22. Figure 47 In one example, the handheld component 24 includes three pairs of rotor magnets that cause the motor 122 to rotate. Figure 48 An ideal representation of example sensing readings SR1, SR2, and SR3 is shown. As shown, the sensing readings SR1, SR2, and SR3 are sinusoidal and have a phase difference of 120 degrees, corresponding to the positions of the rotor magnet pairs on motor 122. Therefore, when the handheld device 24 is connected to the module housing 22, the magnitude of the magnetic field sensed by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) varies sinusoidally.

[0227] Figure 49 Example sensing readings SR1, SR2, and SR3 provided by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) are shown when the control module controller 31 is active and when the charging module 1100 is connected to the module housing 22. Figure 49 In the example, the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) sense the magnet M of the charging module 1100. However, since the charging module 1100 does not rotate when connected to the module housing 22, the magnitude of the magnetic field sensed by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) is a relatively constant value when the charging module 1100 is connected to the module housing 22.

[0228] Figure 50Example sensing readings SR1, SR2, and SR3 provided by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) are shown when the control module controller 31 is active and when the programming jig 1200 is connected to the module housing 22. Figure 50 In the example, the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) sense the magnet 1204 of the programming jig 1200. However, since the programming jig 1200 does not rotate when connected to the module housing 22, the magnitude of the magnetic field sensed by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) is a relatively constant value when the programming jig 1200 is connected to the module housing 22.

[0229] The control module controller 31 can determine whether the module housing 22 is connected to the handheld device 24, the charging module 1100, or the programming fixture 1200 based on the sensing readings SR1, SR2, and SR3 provided by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3). For example, if the magnitude of the magnetic field sensed by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) varies sinusoidally, the control module controller 31 can determine that the handheld device 24 is connected to the module housing 22. If the magnitude of the magnetic field sensed by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) is relatively constant, the control module controller 31 can determine that the charging module 1100 or the programming fixture 1200 is connected to the module housing 22.

[0230] Since the magnitudes of the magnetic fields sensed by the first, second, and third analog Hall effect sensors 32(1), 32(2), and 32(3) are relatively constant when the charging module 1100 is connected to the module housing 22 and when the programming jig 1200 is connected to the module housing 22, the control module controller 31 can use various methods to determine whether the charging module 1100 or the programming jig 1200 is connected to the module housing 22. For example, the control module controller 31 can determine whether the charging module 1100 or the programming jig 1200 is connected to the module housing 22 by comparing the constant values ​​of the sensing readings SR1, SR2, and SR3. For example, when the first sensing reading SR1 is greater than the third sensing reading SR3, for example in... Figure 49 In this example, the control module controller 31 can determine that the charging module 1100 is connected to the module housing 22. For example, when the first sensing reading SR1 is less than the third sensing reading SR3, Figure 50 In this example, the control module controller 31 can determine that the programming fixture 1200 is connected to the module housing 22.

[0231] The positions of magnets M and 1204 can be selected to allow the control module controller 31 to determine whether the charging module 1100 or the programming jig 1200 is connected to the module housing 22. For example, the positions of magnet 1204 of the programming jig 1200 and magnet M of the charging module 1100 can be selected such that the magnitude of the magnetic field generated by magnet 1204 and sensed by analog Hall effect sensor 32 is different from the magnitude of the magnetic field generated by magnet M and sensed by analog Hall effect sensor 32. For example, magnet 1204 can be positioned around the programming jig 1200 and magnet M can be positioned around the protrusion 1104 such that magnet 1204 is aligned with the first analog Hall effect sensor 32 (1) when the programming jig 1200 is connected to the module housing 22 and magnet M is aligned with the third analog Hall effect sensor 32 (3) when the charging module 1100 is connected to the module housing 22.

[0232] The polarity of magnets M and 1204 can be selected to allow the control module controller 31 to determine whether the charging module 1100 or the programming jig 1200 is connected to the module housing 22. For example, the polarity of magnet 1204 of the programming jig 1200 and magnet M of the charging module 1100 can be selected such that the magnitude of the magnetic field generated by magnet 1204 and sensed by analog Hall effect sensor 32 is different from the magnitude of the magnetic field generated by magnet M and sensed by analog Hall effect sensor 32. For example, magnets 404 and 310 can be polarized such that when the programming jig 1200 is connected to the module housing 22, the first analog Hall effect sensor 32(1) senses a positive magnetic field, and when the charging module 1100 is connected to the module housing 22, the first analog Hall effect sensor 32(1) senses a negative magnetic field.

[0233] The control module controller 31 can determine whether the module housing 22 is connected to the handheld device 24, the charging module 1100, or the programming fixture 1200, in order to communicate correctly with the handheld device 24, the charging module 1100, or the programming fixture 1200. For example, one or more of the handheld device 24, the charging module 1100, and the programming fixture 1200 can be configured to communicate with the control module controller 31 using different communication protocols, and can initiate communication using different methods.

[0234] In one example, the control module controller 31 may be configured to communicate with the handheld device 24, the charging module 1100, or the programming fixture 1200 using different communication protocols. In one such example, the control module controller 31 may be configured to communicate with the handheld device 24 using a first communication protocol in response to determining that the module housing 22 is connected to the handheld device 24, and the control module controller 31 may be configured to communicate with the charging module 1100 using a second communication protocol in response to determining that the module housing 22 is connected to the charging module 1100.

[0235] The control module controller 31 can be configured to communicate using a first communication protocol and a second communication protocol at different transmission speeds. For example, the control module controller 31 can be configured to communicate using the first communication protocol at a first transmission speed, and the control module controller 31 can be configured to communicate using the second communication protocol at a second transmission speed. In one such example, the control module controller 31 can be configured to communicate at different baud rates. For example, the control module controller 31 can be configured to communicate using the first communication protocol at 460 kBaud, and simultaneously configured to communicate using the second communication protocol at 19.2 kBaud. It should be noted that the control module controller 31 can be configured to communicate with the handheld device 24, the charging module 1100, and the programming fixture 1200 using any suitable baud rate.

[0236] The control module controller 31 can be configured to communicate using a first communication protocol and a second communication protocol by using different transmission modes. For example, the control module controller 31 can be configured to communicate using the first communication protocol by using full-duplex transmission, and the control module controller 31 can be configured to communicate using the second communication protocol by using half-duplex transmission. It should be noted that the control module controller 31 can be configured to communicate with the handheld device 24, the charging module 1100, and the programming fixture 1200 using any suitable transmission mode (such as full-duplex transmission, half-duplex transmission, and / or simplex transmission).

[0237] In one example, the charging adapter 1102 can be configured to convert the communication protocol used by the charging module 1100 to the communication protocol used by the control module controller 31, such that the control module controller 31 can be configured to communicate with the charging module 1100 via the adapter 1102. In another example, the charging adapter 1102 can be configured to convert the communication protocol used by the control module controller 31 to the communication protocol used by the charging device 1100, such that the control module controller 31 can be configured to communicate with the charging module 1100 via the adapter 1102. Reference Figure 41The first and second adapter communication terminals 1134 and 1136 are shorted to each other within the charging adapter 1102 to allow conversion between the communication protocol used by the charging module 1100 and / or the communication protocol used by the control module controller 31. For example, in an instance where the controller is configured to communicate using a first communication protocol via full-duplex transmission and the charging module 1100 is configured to communicate using a second communication protocol via half-duplex transmission, the charging adapter 1102 can be configured to convert the second communication protocol to the first communication protocol by converting the half-duplex transmission to full-duplex transmission.

[0238] In another example, communication between the control module controller 31 and the handheld device 24, charging module 1100, or programming fixture 1200 connected to the module housing 22 can be initiated by the control module controller 31 or by the handheld device 24, charging module 1100, or programming fixture 1200 connected to the module housing 22. In one such example, the control module controller 31 can be configured to initiate communication between the control module controller 31 and the charging module 1100, and the programming fixture 1200 can be configured to initiate communication between the control module controller 31 and the programming fixture 1200. Specifically, the control module controller 31 can initiate communication by transmitting a communication signal to the charging module 1100 based on the determination that the module housing 22 is connected to the charging module 1100, and the control module controller 31 can be configured to receive a communication signal from the programming fixture 1200 based on the determination that the module housing 22 is connected to the programming fixture 1200.

[0239] Return to reference Figure 44 Once the analog Hall effect sensor 32 no longer senses the magnetic field generated by the handheld device 24, the charging module 1100, or the programming jig 1200, the control module controller 31 can return to sleep mode. For example, when the handheld device 24, the charging module 1100, or the programming jig 1200 is no longer connected to the module housing 22, the analog Hall effect sensor 32 may no longer sense the magnetic field generated by the handheld device 24, the charging module 1100, or the programming jig 1200. In an instance where the digital Hall effect sensor 134 is activated during the active state, once the digital Hall effect sensor 134 no longer senses the magnetic field generated by the handheld device 24, the charging module 1100, or the programming jig 1200, the control module controller 31 can return to sleep mode.

[0240] Powered surgical tools may include a motor or motor body configured to receive power, such as electricity or compressed air, and to convert that power into output torque transmitted via an output shaft. In one embodiment, the powered surgical tool may also include a cannula or be cannulated.

[0241] In one embodiment, the output shaft of the motor may include an inner cavity or a hollow portion, for example, said hollow portion extending through the centerline of the output shaft. The inner cavity may include a first opening at one end of the output shaft and may include a second opening at a second end of the output shaft. A cannula may include a tube at least partially housed within the inner cavity, the tube extending along the centerline of the output shaft. The cannula may have openings at both ends, for example, to allow a device to pass through the cannula. In this disclosure, the distal portion or orientation of a device or component refers to a direction toward the patient. Similarly, the proximal portion or orientation of a device or component refers to a direction away from the patient.

[0242] Motors may include electronic components, such as electromagnets in the rotor and stator, and wires that electrically connect parts of the motor to other parts of the motor or to terminals extending out of the motor.

[0243] A powered surgical tool is provided, comprising a motor including a cannula disposed therein, wherein the powered surgical tool further comprises a housing, a sealing plug, and a shaft seal, wherein the sealing plug and the shaft seal are configured to prevent liquids used during autoclaving from entering the interior of the powered surgical tool, while allowing surgical devices (such as wires or pins) to pass through the cannula.

[0244] In one implementation, the attachment to the powered surgical tool can be described as a surgical handpiece or handheld device.

[0245] In one embodiment, a pistol grip (or stick or tool handle) may include a battery and a control module, and may be described as a battery and control module (BMC) as described throughout this disclosure.

[0246] Figure 51 An exemplary battery and control module 1300 configured as a pistol grip is shown in the previous perspective view. The battery and control module 1300 includes a module cavity 1301 or hollow cavity portion configured to receive a surgical handpiece or attachment. The module cavity 1301 can be described as a module cavity. Figure 52 The following perspective view is shown. Figure 51 The battery and control module 1300 includes a cannula access point 1302 configured to provide external access to a cannula disposed within the surgical handpiece, which can be loaded into... Figure 51 It is located in the inner cavity 1301 of the module.

[0247] Figure 53 It shows the configuration used to set Figure 51A surgical handpiece 1310 is located within the module cavity 1301 of a battery and control module 1300. The surgical handpiece 1310 includes a housing 1320 configured to receive and physically protect components housed therein, and features 1312 for physical connection at one end to the battery and control module 1300 and at a second end to a surgical handpiece attachment. The second end may include a tool connector, or may be configured to attach to a tool connector. A sealing plug 1360 is shown sealing the end of the surgical handpiece 1310. A cannula cavity 1344 is shown exposed at this end of the surgical handpiece 1310. A powered surgical tool can be described as including a battery and control module 1300, which includes... Figure 51 The module cavity 1301, in which Figure 53 The surgical handpiece 1310 is inserted into the inner cavity 1301 of the module.

[0248] Figure 54 It shows Figure 53 A cross-section of the surgical handpiece 1310 is shown. The surgical handpiece 1310 is shown as including a housing 1320, an internal structure insert 1322, a circuit board 1350, a motor 1330, a sleeve 1340, and terminals 1352, 1353 protruding into the surgical handpiece 1310. The internal structure insert 1322 may be metal, plastic, or some other similar material, and holds multiple illustrated components in place relative to the housing 1320. The internal structure insert 1322 can be considered as part of the housing 1320. The internal structure insert 1322 can be configured to provide different positions and function as a positioning clamp for the circuit board 1350, sleeve 1340, output shaft 1332, and other parts of the illustrated surgical handpiece 1310. The internal structure insert 1322 includes an inner diameter at a first proximal end of the surgical handpiece 1310. Terminals 1352, 1353 electrically connect the circuit board 1350 to external electronic components, such as... Figure 51 The battery and control module 1300 contain connectors. Power can be supplied to the circuit board 1350 and the motor 1330 via terminals 1352 and 1353.

[0249] Motor 1330 includes an output shaft 1332 mechanically connected to motor rotor structure 1336 and configured to provide output torque from motor 1330. Motor also includes a connector plate 1338 comprising an exemplary copper layer configured to provide electrical connections to portions of motor 1330. Output shaft 1332 is hollow and includes an inner cavity 1334 in which a cannula 1340 is disposed. The cannula includes the cannula inner cavity 1344 at a first proximal end and includes a second end 1342 extending outwardly from a front or distal end of surgical handpiece 1310. Cannula 1340 also includes a cannula flange 1346 that facilitates positioning of cannula 1340 and interacts with sealing components, sealing plug 1360, and sealing element 1370 of surgical handpiece.

[0250] Components of the surgical handpiece 1310, located within the surgical handpiece 1310, may be sensitive or subject to increased abrasion if exposed to high temperatures and / or liquids during sterilization or cleaning processes. A sealing plug 1360 and a seal 1370 are configured to prevent liquid ingress into the interior of the surgical handpiece 1310. The sealing plug 1360 may be made of plastic or a rigid polymer. The sealing plug 1360 may press-fit within the inner diameter of an internal structure insert 1322, wherein friction and compression between the sidewalls 1362 of the sealing plug 1360 retain the sealing plug 1360 within the surgical handpiece 1310. The sealing plug 1360 may include a terminal through point 1364, configured to allow terminals 1352, 1353 to enter the internal portion of the surgical handpiece 1310 while maintaining a seal.

[0251] The sleeve 1340 passes through the sealing plug 1360. A seal 1370 is provided so that the sleeve 1340 can seal against the sealing plug 1360. The seal 1370 is shown as having an outer cylindrical shape and including a hollow portion or being configured to receive the sleeve 1340 within a sealing cavity in the hollow portion. The cylindrical shape of the rubber-covered seal 1370 may include the same longitudinal axis as the sleeve 1340. A first sealing surface 1372 is disposed on the end surface of the cylindrical shape of the seal 1370, forming a seal between the opposing or mating surfaces of the seal 1370 and the sealing plug 1360. A second sealing surface 1374 is configured as an annular (ring-shaped) surface on the inner diameter of the seal 1370, which is configured to seal against the outer radial surface of the sleeve 1340. The seal 1370 may be arranged to contact the sleeve flange 1346.

[0252] The tool connector can be attached to the output shaft 1332.

[0253] A socket stop 1380 is disposed around the outside of the internal structure insert 1322 and the sealing plug 1360. The socket stop 1380 can be configured to retain the sealing plug 1360 within the inner diameter of the internal structure insert 1322 if the press fit between the sealing plug 1360 and the internal structure insert 1322 is not maintained or is released.

[0254] Figure 55 An embodiment of a powered surgical tool 1400 is shown, wherein the device housing 1420 of the battery and control module 1410 is designed to provide improved ergonomics and usability. The powered surgical tool 1400 also includes a handpiece configured to be detachably coupled to the battery and control module 1410 within a handpiece cavity 1430. The battery and control module 1410 may include a battery 1415 housed therein and may also include a circuit board configured to provide functionality of the powered surgical tool 1400, such as selectively powering the handpiece or unit mounted to the handpiece cavity 1430 from the battery 1415. The battery 1415 may include one or more battery cells. The handpiece may include a modular motor and drivetrain (not identified) and may include other sub-components such as electrical connectors, gearboxes, and geometry for detachably receiving cutting attachments including a head. The handpiece may include a modular motor and may be configured to supply power to a surgical end effector (such as a bone drill, saw, drill, or other similar device). Apart from certain features of the handheld device that will be described in further detail, the handheld device may take the form disclosed in the jointly owned International Publication No. WO2013 / 177423, published on 28 November 2013, the entire contents of which have been previously incorporated herein by reference.

[0255] The cutting attachment assembly may be unique for complementary forms of motors and drivetrains to provide a set of handpieces configured to selectively and interchangeably connect with the battery and control module 1410. Any device or attachment applied to a surgical site, whether a sagittal saw blade or a drill bit, can generally be referred to as an energy applicator. In other embodiments, the powered surgical tool 1400 may be a rotary drill, reamer, wire driver, oscillating or reciprocating saw, ultrasonic device, or photonic device. Similarly, the energy applicator may be a drill bit, bone drill, saw, reamer, grinding disc, ultrasonic cutting or catheter insertion tip, laser, etc. The type of tool used is not intended to limit the invention. The motor may be a general-purpose motor that can interchangeably receive more than one cutting attachment, as described below. The powered surgical tool 1400 of this disclosure is particularly suitable for orthopedic surgeries involving the arm, hand, leg, foot, mandible, and skull, but other minor bone orthopedic and soft tissue surgeries are also contemplated.

[0256] The battery and control module 1410 includes at least one battery and a main controller coupled to a printed circuit board assembly, as will be discussed in more detail below. The main controller communicates with the battery (which may be part of the battery assembly), a motor control sensor, and a manual switch sensor, and is also configured to communicate with the motor when the handpiece is detachably coupled to the battery and control module 1410. The main controller may also communicate with a memory device. The battery and control module 1410 may include a manual switch assembly optionally coupled to the device housing 1420 and configured to receive input from a user to operate the powered surgical tool 1400. For example, the manual switch assembly may be spring-loaded and include a manual switch magnet such that when the manual switch assembly is actuated, the manual switch magnet moves toward a manual switch sensor. While an example of a manual switch assembly coupled to the battery and control module 1410 is provided, the manual switch assembly may be detachable and attached to any part of the battery and control module 1410 and / or the handpiece. Furthermore, the manual switch assembly may be part of or attached to the handpiece.

[0257] The battery and control module 1410 includes a barrel 1440 and a handle 1450. The handle 1450 extends downward from the barrel 1440. The battery and control module 1410 may have two triggers 1460, 1470, or switches, which are spring-loaded and externally mounted on or attached to the battery and control module 1410. The two triggers 1460, 1470 extend forward from the distal portion of the handle 1450. A medical practitioner can actuate the triggers 1460, 1470 to control the operation of the tool unit. The triggers 1460, 1470 may each include a magnet that moves when the triggers 1460, 1470 are actuated by the user, as discussed in more detail below. The battery and control module 1410 may include a pressure relief valve and a cap.

[0258] Figure 56 The internal components of the battery and control module 1410 are shown in a side perspective view, including those corresponding to... Figure 55 A pair of trigger sensors 1520 and 1530 are provided for triggers 1460 and 1470. Trigger sensors 1520 and 1530 can be configured to monitor or detect the presence or proximity of a magnetic field generated by a permanent magnet, which can be detected through the housing wall. (Diagram shown) Figure 55The device housing 1420 includes an intermediate housing 1500. Trigger sensors 1520 and 1530 may be disposed on or included within a printed circuit board 1510. Trigger sensors 1520 and 1530 may be Hall effect sensors. The printed circuit board 1510 is disposed within a handle 1450. Specifically, the printed circuit board 1510 is positioned close to triggers 1460 and 1470, such that multiple trigger sensors 1520 and 1530 can sense the state of triggers 1460 and 1470, for example, when triggers 1460 and 1470 have been actuated by a user.

[0259] Multiple motor control sensors can be coupled to another or a second printed circuit board connected to the battery and control module 1410. The motor control sensors can be Hall effect type. A switching module comprising multiple metal-oxide-semiconductor field-effect transistors (MOSFETs) can also be coupled to the second printed circuit board. Although this disclosure contemplates MOSFETs as switching components coupled to the second printed circuit board, other suitable transistors or switching components can be used. The switching module can be used to control the operating direction of the handheld device's motor, for example, in a forward or reverse direction.

[0260] Figure 57 The rear perspective view of the front housing 1600 is shown, which is configured to be assembled, welded, laser-attached, or otherwise attached to Figure 56 The handle portion of the intermediate housing 1500. The front housing 1600 is shown as including a portion configured to accommodate... Figure 55 The structures 1620 and 1630 of the triggers 1460 and 1470, as well as springs and other hardware configured to align and actuate the triggers 1460 and 1470, are shown. Additionally, a recess 1640 or cutout area is shown as configured to accommodate... Figure 56The trigger sensors 1520 and 1530 are configured to be accessible to triggers 1460 and 1470. A recess 1640 may include a space for housing the trigger sensors 1520 and 1530, while a wall of the front housing 1600 is disposed between the trigger sensors 1520 and 1530 and the triggers 1460 and 1470. This seals the battery and control module 1410 to prevent liquid ingress, while simultaneously enabling signal interaction between the triggers 1460 and 1470 and their corresponding trigger sensors 1520 and 1530. The front housing 1600 may be continuous, without any through-holes in the areas of structures 1620 and 1630 and the recess 1640. The magnetic interaction between triggers 1460 and 1470 and their corresponding trigger sensors 1520 and 1530 enables the detection of pressing of triggers 1460 and 1470 or the generation of their corresponding signals, while maintaining the sealed housing between triggers 1460 and 1470 and trigger sensors 1520 and 1530.

[0261] refer to Figures 55-57 The printed circuit board 1510 can be assembled with the trigger sensors 1520 and 1530 on the intermediate housing 1500, and the front housing 1600, including the recess 1640, can be soldered, laser-attached, or otherwise attached to accommodate the trigger sensors 1520 and 1530, thereby sealing the battery and control module 1410 before the triggers 1460 and 1470 are assembled to the battery and control module 1410. It will be understood that the triggers 1460 and 1470 can be replaced or refurbished later without compromising the seal of the battery and control module 1410.

[0262] Figure 58 A side perspective view shows a sealed housing assembly 1610, which includes a front housing 1600 attached to an intermediate housing 1500 by means of sealing welding, laser process attachment, adhesion, fastening, or other methods. The sealed housing assembly 1610 may include multiple housings hermetically connected together and configured to encapsulate components therein. The housings of the disclosed battery and control module 1410 may be made of polymer, and welding may refer to a joining process such as vibration welding, in which the contact surfaces of the housings are locally heated and joined. The sealed housing assembly 1610 of the battery and control module 1410 allows the sealed housing assembly 1610 to be sterilized, for example, by an autoclaving process, without the heating liquid of the sterilization process entering the sealed housing assembly 1610 and not contacting its components (such as circuit boards and battery 1415).

[0263] Figure 59 It shows Figure 58A side perspective view of the sealed housing assembly 1610, wherein triggers 1460 and 1470 are mounted to the sealed housing assembly. Trigger 1460 is shown in at least a partially unpressed state, and trigger 1470 is shown in at least a partially pressed state.

[0264] Figure 60 It is shown in the disassembled state. Figure 59 The sealed housing assembly 1610 and triggers 1460, 1470 are shown. Trigger hardware component 1700 is shown, including a spring, a trigger lock translation plate, and alignment hardware configured to enable assembly and selective actuation of triggers 1460, 1470. Trigger hardware component 1700 may include a front plate 1710 and screws 1720 configured for installation and removal, allowing easy installation and later replacement of triggers 1460, 1470. Triggers 1460, 1470 can be held in place by the front plate 1710 and screws 1720. Each of triggers 1460, 1470 is shown as including a circular or cylindrical rod portion 1462, 1472. The sealed housing assembly 1610 is shown as including a pair of trigger cavities 1612, 1614, respectively configured to receive rod portions 1462, 1472. The lever portions 1462 and 1472 can be described as being configured to engage with the trigger cavities 1612 and 1614.

[0265] Figure 61 A side sectional view shows a portion of triggers 1460, 1470, and a sealed housing assembly 1610. A circuit board 1510 is also shown. Each trigger may include components for directing... Figure 56 The trigger sensors 1520 and 1530 provide control signals to the magnets 1730 and 1732.

[0266] Figure 62 A front sectional view of the trigger 1470 and a portion of the sealed housing assembly 1610 is shown. The trigger 1470 is shown as including a magnet 1730. Also shown is... Figure 56 The corresponding trigger sensor 1530. Additionally, a screw boss feature 1618 is shown, configured to receive... Figure 60 Screw 1720.

[0267] Triggers 1460 and 1470 can be selectively pressed for actuation. Figure 55 1400 surgical tools. Figure 60The triggers 1460, 1470 may include rod portions 1462, 1472 configured for mounting into the corresponding trigger cavities 1612, 1614. In some examples, air trapped between the triggers 1460, 1470 and the walls of the trigger cavities 1612, 1614 may inhibit free movement of the triggers 1460, 1470 relative to the sealed housing assembly 1610.

[0268] Figure 63 A front perspective view of a portion of a sealed housing assembly 1610 including a plurality of trigger vent cutouts 1660, 1670 is shown. Each of the trigger vent cutouts 1660, 1670 may include a channel formed in the wall of the sealed housing assembly 1610, the channel being configured to... Figure 60 When each of the triggers 1460 and 1470 is installed or pressed, air is released from its rear. The trigger vents 1660 and 1670 allow air to be released from the rear of each of the triggers 1460 and 1470 while keeping the sealed housing assembly 1610 a sealed unit.

[0269] Figure 64 The previously shown sectional view illustrates a portion of the sealed housing assembly 1610, including lever portions 1462, 1472 and corresponding trigger vent cutouts 1660, 1670. Lever portions 1462, 1472 are fit snugly to the surfaces of the corresponding trigger cavities 1612, 1614, while trigger vent cutouts 1660, 1670 provide space for air to enter from the trigger. Figure 60 The path of flow following triggers 1460 and 1470.

[0270] Figure 65 This is a flowchart illustrating a method 1800 for operating a powered surgical tool. Method 1800 uses... Figure 55The battery and control module 1410 are provided, but other examples of surgical tools may also be used according to method 1800. Method 1800 begins at step 1802. At step 1804, method 1800 includes providing a battery and control module 1410 comprising a sealed housing assembly 1610. The sealed housing assembly 1610 encapsulates a printed circuit board 1510 including at least one trigger sensor 1520 and includes at least one trigger cavity 1612 configured to receive a trigger 1460. At step 1806, method 1800 continues by mounting at least one trigger 1460 into the trigger cavity 1612, the trigger 1460 including a rod portion 1462 having at least one magnet 1530 configured to interact with the trigger sensor 1520 without compromising the seal of the sealed housing assembly 1610. At step 1808, method 1800 ends. Many additional and / or alternative method steps are envisioned, and method 1800 is not intended to be limited to the examples provided herein.

[0271] Figure 66 This is a flowchart illustrating method 1900 for repairing powered surgical instruments. Method 1900 uses... Figure 55 The battery and control module 1410 is provided, but other examples of surgical tools may also be used according to method 1900. Method 1900 begins at step 1902. At step 1904, method 1900 includes providing a battery and control module 1410 comprising a sealed housing assembly 1610. The sealed housing assembly 1610 encapsulates a printed circuit board 1510 including at least one trigger sensor 1520. The battery and control module 1410 includes at least one trigger 1460 including a magnet 1530. At step 1906, method 1900 continues by removing the trigger 1460 from the battery and control module 1410 without compromising the seal of the sealed housing assembly 1610. At step 1908, method 1900 ends. Many additional and / or alternative method steps are contemplated, and method 1900 is not intended to be limited to the examples provided herein.

[0272] The broad teachings of this disclosure can be implemented in various forms. Therefore, while this disclosure includes specific examples, its true scope should not be limited thereto, as other modifications will become apparent upon examination of the drawings, description, and subsequent claims. It should be understood that one or more steps within the method may be performed in different orders (or simultaneously) without altering the principles of this disclosure. Furthermore, although each example is described above as having certain features, any one or more of those features described with respect to any example of this disclosure may be implemented in and / or combined with features of any other example, even if such combination is not explicitly described. In other words, the described examples are not mutually exclusive, and permutations and combinations of one or more examples remain within the scope of this disclosure.

[0273] Spatial and functional relationships between components (e.g., between controllers, circuit elements, semiconductor layers, etc.) are described using various terms, including “connected,” “joined,” “linked,” “adjacent,” “closely adjacent,” “above,” “under,” and “set.” Unless explicitly described as “direct,” when describing the relationship between the first and second components in the foregoing disclosure, the relationship can be a direct relationship in which no other intermediate components exist between the first and second components, or an indirect relationship (spatially or functionally) in which one or more intermediate components exist between the first and second components.

[0274] As used herein, the phrase "at least one of A, B, and C" should be interpreted as indicating the use of non-exclusive OR logic (A or B or C), and should not be interpreted as indicating "at least one of A, at least one of B, and at least one of C". A subset of terms does not necessarily require an appropriate subset. In other words, a first subset of the first set can be co-extended (equal to) the first set.

[0275] In the accompanying drawings, the direction of the arrows (as indicated by the arrows) typically illustrates the flow of information (such as data or instructions) of interest to the illustration. For example, when components A and B exchange various types of information, but the information sent from component A to component B is relevant to the illustration, the arrow can point from component A to component B. This unidirectional arrow does not imply that no other information is being sent from component B to component A. Furthermore, for information sent from component A to component B, component B can send a request for the information to component A or receive confirmation of the information.

[0276] In this application, the terms "controller" or "module" may be replaced by the term "circuit" as defined below. The term "controller" may refer to, be part of, or include the following: Application-Specific Integrated Circuit (ASIC); Programmable System-on-Chip (PSoC); Digital, Analog, or Mixed-Signal / Digital Discrete Circuit; Digital, Analog, or Mixed-Signal / Digital Integrated Circuit; Combinational Logic Circuit; Field-Programmable Gate Array (FPGA); Processor Circuit (Shared, Dedicated, or Group) that executes code; Memory Circuit (Shared, Dedicated, or Group) that stores code executed by the processor circuit; Other suitable hardware components that provide the described functionality; or some or all of the foregoing, such as in a System-on-Chip.

[0277] The controller may include one or more interface circuits having one or more transceivers. In some examples, the interface circuits may implement wired or wireless interfaces for connection to a local area network (LAN) or a wireless personal area network (WPAN). Examples of LANs are the Institute of Electrical and Electronics Engineers (IEEE) standard 802.11-2016 (also known as the Wi-Fi wireless network standard) and the IEEE standard 802.3-2015 (also known as the Ethereum wired network standard). Examples of WPANs are the Bluetooth Special Interest Group's BLUETOOTH wireless network standard and the IEEE standard 802.15.4.

[0278] The controller can communicate with other controllers using interface circuitry. Although the controller may be depicted in this disclosure as communicating directly with other controller logic, in various embodiments, the controller may actually communicate via a communication system. The communication system may include physical and / or virtual network devices such as hubs, switches, routers, gateways, and transceivers. In some embodiments, the communication system is connected to or traverses a wide area network (WAN), such as the Internet. For example, the communication system may include multiple LANs interconnected via the Internet or peer-to-peer leased lines using technologies including Multiprotocol Label Switching (MPLS) and Virtual Private Networks (VPNs).

[0279] In various implementations, the functionality of the controller can be distributed among multiple controllers connected via a communication system. For example, multiple controllers can perform the same functionality assigned by a load balancing system. In another example, the functionality of the controller can be split between a server (also known as a remote or cloud) controller and a client (or user) controller.

[0280] Some or all of the controller's hardware characteristics can be defined using a language for hardware description, such as IEEE Standard 1364-2005 (commonly referred to as "Verilog") and IEEE Standard 1076-2008 (commonly referred to as "VHDL"). Hardware description languages ​​can be used to manufacture and / or program hardware circuits. In some implementations, some or all of the controller's characteristics can be defined by a language such as IEEE 1666-2005 (commonly referred to as "SystemC"), which includes code and hardware description as described below.

[0281] The term "code" as used above can include software, firmware, and / or microcode, and can refer to programs, routines, functions, classes, data structures, and / or objects. The term "shared processor circuit" covers a single processor circuit that executes some or all of the code from multiple controllers. The term "group processor circuit" covers a processor circuit that, in combination with other processor circuits, executes some or all of the code from one or more controllers. The reference to "multiple processor circuits" covers multiple processor circuits on a discrete die, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or a combination of the above. The term "shared memory circuit" covers a single memory circuit that stores some or all of the code from multiple controllers. The term "group memory circuit" covers a memory circuit that, in combination with other memories, stores some or all of the code from one or more controllers.

[0282] The term memory circuitry is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not cover transient electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); therefore, the term computer-readable medium can be considered tangible and non-transient. Non-limiting examples of non-transient computer-readable media are non-volatile memory circuitry (such as flash memory circuitry, erasable programmable read-only memory circuitry, or mask read-only memory circuitry), volatile memory circuitry (such as static random access memory circuitry or dynamic random access memory circuitry), magnetic storage media (such as analog or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0283] The apparatus and methods described in this application can be implemented, in part or in whole, by a special-purpose computer created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. The aforementioned function blocks and flowchart elements can be used as software specifications, which can be converted into computer programs through the routine work of skilled technicians or programmers.

[0284] A computer program includes processor-executable instructions stored on at least one non-transitory computer-readable medium. A computer program may also include or depend on stored data. A computer program may include a basic input / output system (BIOS) that interacts with the hardware of a special-purpose computer, device drivers that interact with specific devices of the special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0285] Computer programs may include: (i) descriptive text to be parsed, such as HTML (Hypertext Markup Language), XML (Extensible Markup Language), or JSON (JavaScript Object Notation); (ii) assembly code; (iii) object code generated from source code by a compiler; (iv) source code executed by an interpreter; and (v) source code compiled and executed by a just-in-time (JIT) compiler, etc. As an example only, source code can be written using syntax from languages ​​including: C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, etc. Fortran, Perl, Pascal, Curl, OCaml, HTML5 (Hypertext Markup Language, 5th Revision), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Visual Lua, MATLAB, SIMULINK and

Claims

1. A powered surgical tool, comprising: A handheld device, the handheld device including a motor and a tool connector, the handheld device defining at least one of a track and a slot, and the handheld device further defining a receiver surface; and The battery and control module include: The device housing includes another of the track and slot, the track and slot being configured such that the track is slidable within the slot to allow connection between the handpiece and the battery and control module, the device housing also defining a clearance space; A rechargeable battery module, wherein the rechargeable battery module is disposed in the gap space; A printed circuit board assembly, the printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly also including a motor sensor configured to output a motor sensor signal indicating the state of the motor; and At least three conductive terminals extend through the device housing to establish an electrical connection between the printed circuit board assembly and the handheld device.

2. The powered surgical tool of claim 1, wherein the handpiece defines a cannula, and wherein the device housing is without a cannula.

3. The powered surgical tool according to any of the preceding claims, wherein the battery and control module include a safety vent.

4. The powered surgical tool according to any of the preceding claims, wherein the motor is an electric motor.

5. The powered surgical tool according to any of the preceding claims, wherein the motor sensor is further defined as a Hall effect sensor.

6. The powered surgical tool according to any of the preceding claims, wherein the handheld component includes a memory device electrically connected to at least one of the at least three conductive terminals.

7. The powered surgical tool according to any of the preceding claims, wherein the distal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

8. The powered surgical tool according to any of the preceding claims, wherein a portion of the proximal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

9. The powered surgical tool according to any of the preceding claims, wherein the battery and control module includes a latch assembly comprising a locking member and a biasing member, the biasing member being positioned to push the locking member toward the receiver surface.

10. A powered surgical tool, comprising: A handheld component, the handheld component including a motor and a tool connector, wherein the handheld component defines a sleeve; and The battery and control module include: Device housing, the device housing defining a void space; A rechargeable battery module is disposed in the void space; A printed circuit board assembly, the printed circuit board assembly including a controller configured to regulate power drawn from the rechargeable battery module based on user input, the printed circuit board assembly also including a motor sensor configured to output a motor sensor signal indicating the state of the motor; and At least three conductive terminals extending through the device housing are provided for establishing an electrical connection between the printed circuit board assembly and the handheld component. The battery and control module described herein are not fitted with sleeves.

11. The powered surgical tool of claim 10, wherein the battery and control module include a safety vent.

12. The powered surgical tool according to any one of claims 10 and 11, wherein the motor is an electric motor.

13. The powered surgical tool according to any one of claims 10-12, wherein the motor sensor is further defined as a Hall effect sensor.

14. The powered surgical tool according to any one of claims 10-13, wherein the handheld component includes a memory device electrically connected to at least one of the at least three conductive terminals.

15. The powered surgical tool according to any one of claims 10-14, wherein the distal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

16. The powered surgical tool of claim 15, wherein a portion of the proximal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

17. A surgical handpiece for coupling to a battery and a control module, the surgical handpiece comprising: case; Tool connector; An electric motor is installed inside the housing; A rotor defining an axis, the rotor being connected to the electric motor and the tool connector; The system includes a rigid circuit board for the controller, the rigid circuit board being disposed within the housing and oriented perpendicular to the axis of the rotor; and Multiple terminals extend through the housing and engage the rigid circuit board.

18. The surgical handpiece of claim 17, wherein the handpiece includes a memory device electrically connected to at least one of the plurality of terminals.

19. The surgical handpiece according to any one of claims 17 and 18, wherein the surgical handpiece defines a longitudinal axis and the surgical handpiece defines a cannula surrounding the longitudinal axis.

20. The surgical handpiece of claim 19, wherein the rigid circuit board defines an orifice surrounding the sleeve.

21. The surgical handpiece of claim 20, wherein the orifice and the sleeve are coaxial.

22. A surgical handpiece for coupling to a battery and a control module, the surgical handpiece comprising: case; Tool connector; An electric motor is installed inside the housing; A rotor defining an axis, the rotor being connected to the electric motor and the tool connector; The circuit board includes a controller, the circuit board being disposed within the housing, the circuit board including a rigid portion and a flexible portion, the rigid portion defining an axis oriented parallel to the axis of the rotor; and Multiple terminals extend through the housing and engage the flexible portion of the circuit board.

23. The surgical handpiece of claim 22, wherein the handpiece includes a memory device electrically connected to at least one of the plurality of terminals.

24. A powered surgical tool, comprising: Including the handheld component of the motor; and The battery and control module include: The device housing has a recess for removably receiving the handheld component, and the device housing defines a cavity space; A rechargeable battery module is disposed in the void space; A first printed circuit board, which is disposed in the void space and is rigid; A second printed circuit board, disposed within the void space and being rigid, is coupled to the first printed circuit board. The second and first printed circuit boards are arranged in a stacked configuration. Multiple motor control sensors are connected to the second printed circuit board. A controller, configured to regulate the power drawn from the rechargeable battery module based on user input, is mounted on one of the first and second printed circuit boards.

25. The powered surgical tool of claim 24, wherein the battery and control module further comprises a third printed circuit board connected via a conductor to one of the first and second printed circuit boards, wherein the third printed circuit board includes at least three conductive terminals that extend at least partially through the device housing to establish an electrical connection between the third printed circuit board and the handpiece.

26. The powered surgical tool of claim 25, wherein the device housing defines a mounting post, and the third printed circuit board abuts the mounting post such that the axial position of the third printed circuit board is controlled within the battery and control module.

27. The powered surgical tool of claim 26, wherein the at least three conductive terminals are soldered to the third printed circuit board.

28. The powered surgical tool according to any one of claims 24-27, wherein the conductor is further defined as a flexible circuit.

29. The powered surgical tool according to any one of claims 24-28, wherein the battery and control module further comprises a plurality of support ribs and a plate mount, the plate mount including a plurality of wings for engaging the support ribs.

30. The powered surgical tool according to any one of claims 24-29, wherein the battery and control module further includes a plate mount, the plate mount including one of a set of recesses or a set of protrusions, and the device housing defining the other of the set of recesses or the set of protrusions, wherein the set of protrusions engages the set of recesses to prevent the plate mount from moving relative to the device housing in multiple degrees of freedom.

31. The powered surgical tool of claim 30, wherein one of the set of notches and / or the set of protrusions is positioned in an arcuate arrangement relative to each other.

32. The powered surgical tool according to any one of claims 24-31, wherein the plate mount includes the set of protrusions, and each of the set of protrusions defines a slot for securing one of the plurality of motor control sensors.

33. The powered surgical tool of claim 30, wherein the motor comprises a plurality of magnets, and wherein the device housing comprises the set of notches defining a series of notch peaks and notch valleys, wherein the innermost surface of the notch peaks is further away from the magnets of the motor than the innermost surface of the notch valleys.

34. The powered surgical tool according to any one of claims 24-33, wherein the first printed circuit board has a larger surface area than the second circuit board.

35. The powered surgical tool according to any one of claims 24-34, wherein when the handpiece is coupled to the battery and control module, the first printed circuit board is further away from the motor than the second circuit board.

36. The powered surgical tool according to any one of claims 24-35, wherein the first printed circuit board and the second printed circuit board are interconnected using a board connector.

37. The powered surgical tool according to any one of claims 24-36, wherein the second printed circuit board includes two main sides, and wherein the board mount contacts only one of the two main sides.

38. The powered surgical tool of claim 37, wherein the second printed circuit board includes at least four secondary sides, wherein the board mount contacts two or fewer secondary sides of the second printed circuit board.

39. The powered surgical tool of claim 37, wherein the second printed circuit board includes at least four secondary sides, wherein the board mount does not contact the secondary sides of the second printed circuit board.

40. The powered surgical tool of claim 37, wherein the plate mount includes a body portion and a flange defining a hole for inserting a fastener, the flange extending perpendicularly from the body portion.

41. The powered surgical tool of claim 40, wherein the battery and control module further comprises a plurality of spacers disposed between the first printed circuit board and the second printed circuit board.

42. The powered surgical tool of claim 41, wherein each of the plurality of spacers defines an aperture, wherein the battery and control module includes a plurality of fasteners arranged to extend through the first printed circuit board, the aperture of at least one of the plurality of spacers, and the second printed circuit board.

43. The powered surgical tool of claim 42, wherein the plate mount defines a plurality of mounting holes, each of the plurality of mounting holes including a threaded insert.

44. The powered surgical tool according to any one of claims 24-43, wherein the third printed circuit board includes a light source, and the device housing includes a light guide aligned with the light source.

45. A powered surgical tool, comprising: Including the handheld component of the motor; and The battery and control module include: The device housing has a recess for removably receiving the handheld component, and the device housing defines a cavity space; A rechargeable battery module is disposed in the void space; A printed circuit board assembly disposed in the void space, the printed circuit board assembly including a rigid portion; Multiple motor control sensors are disposed on the rigid portion of the printed circuit board assembly; and A controller, configured to regulate the power drawn from the rechargeable battery module based on user input, is mounted on the printed circuit board assembly.

46. ​​The powered surgical tool of claim 45, wherein the battery and control module further comprises a plate mount, wherein the plate mount includes one of a set of recesses or a set of protrusions, and the device housing defines the other of the set of recesses or the set of protrusions, wherein the set of protrusions engages the set of recesses to prevent the rigid portion of the printed circuit board assembly from moving relative to the device housing in two or more degrees of freedom.

47. The powered surgical tool of claim 46, wherein one of the set of notches and / or the set of protrusions is positioned in an arcuate arrangement relative to each other.

48. The powered surgical tool of claim 46, wherein the plate mount includes the set of protrusions, and each of the set of protrusions defines a slot for securing one of the plurality of motor control sensors.

49. The powered surgical tool of claim 47, wherein the motor comprises a plurality of magnets, wherein the device housing comprises the set of notches defining a series of notch peaks and notch valleys, wherein the innermost surface of the notch peaks is further away from the plurality of magnets of the motor than the innermost surface of the notch valleys.

50. A powered surgical tool, comprising: A handheld device including a motor, the motor including a plurality of magnets; and The control module includes: A device housing for detachably receiving the handheld device, the device housing defining a void space; First terminal; A sensor configured to provide a sensor signal, the sensor being positioned to sense at least one of the plurality of magnets when the handheld device is received; and A controller is configured to regulate the power supplied to the first terminal based on the sensor signal.

51. The powered surgical tool of claim 50, wherein the sensor is further defined as a first set of sensors, wherein when the handpiece is received in the control module, the first set of sensors is axially aligned with at least a portion of one of the plurality of magnets.

52. The powered surgical tool according to any one of claims 50 and 51, wherein the first set of sensors is a digital Hall effect sensor.

53. The powered surgical tool according to any one of claims 50-52 further comprises a second set of sensors, wherein the second set of sensors is a simulated Hall effect sensor.

54. The powered surgical tool of claim 53, wherein the controller is configured to energize the first terminal based on the first set of sensors, and wherein the controller is configured to commutate the motor based on the second set of sensors.

55. The powered surgical tool of claim 53, wherein each sensor in the first set of sensors is aligned with each other.

56. The powered surgical tool of claim 53, wherein each sensor in the second set of sensors is aligned with each other.

57. The powered surgical tool of claim 56, wherein the first set of sensors is axially offset from the second set of sensors.

58. The powered surgical tool of claim 56, wherein the controller is configured to switch between a sleep state and an active state, wherein the powered surgical tool is configured to cause the controller to switch from the sleep state to the active state based on the sensor signal.

59. The powered surgical tool of claim 58 further includes a second terminal, the second terminal being energized when the controller is in the sleep state and the active state.

60. The powered surgical tool of claim 59, wherein the handpiece includes a memory device and a data terminal electrically communicating with the memory device, and wherein the data terminal is configured to connect to the second terminal of the control module when the handpiece is received in the recess.

61. The powered surgical tool of claim 59, wherein when the controller is in the sleep state, the powered surgical tool has a current consumption of less than 5 mA.

62. The powered surgical tool according to any one of claims 50-61, wherein the motor comprises a motor rotor, a stack of laminations surrounding the rotor, and a plurality of magnets surrounding the rotor, wherein a portion of the plurality of magnets extends axially beyond the stack of laminations.

63. The powered surgical tool according to any one of claims 50-62, wherein the control module is further defined as a battery and a control module, wherein the battery and control module further comprises a rechargeable battery module.

64. A powered surgical tool with a pencil-grip configuration, the powered surgical tool comprising: A plastic housing defining an integral mounting base, the integral mounting base defining a first opening and a second opening. A first pin and a second pin, the first pin and the second pin extending through the first orifice and the second orifice respectively, wherein the first pin defines a pivot axis and a pivot surface, and the first pin and the second pin define a press-fit engagement with each other; and A lever, which is pivotally connected to the pivoting surface of the first pin.

65. The powered surgical tool of claim 64, wherein the plastic housing defines a first recess adjacent to the first orifice, wherein the first recess includes a first flat surface, wherein the first pin includes a head and a shaft extending from the head, wherein the head includes a second flat surface, and the first pin is positioned within the first orifice such that the second flat surface of the head engages the first flat surface of the first recess.

66. The powered surgical tool of claim 65 further comprises a torsion spring, the torsion spring comprising a coil, a first leg, and a second leg, wherein the first leg and the second leg extend from opposite ends of the coil, wherein the coil surrounds the first pin.

67. The powered surgical tool of claim 65, wherein the plastic housing defines a channel, wherein the lever is pivotable about the first pin between a first fully pressed position and a second unpressed position, and wherein the lever is at least partially disposed within the channel in both the first fully pressed position and the second unpressed position.

68. The powered surgical tool according to claim 65, further comprising: Including the handheld component of the motor; Furthermore, the plastic housing defines a recess for removably receiving the handheld component, and the plastic housing defines a void space; A printed circuit board disposed in the void space; A rechargeable battery module is disposed in the void space; The lever is configured to receive input from a user to draw power from the rechargeable battery module and supply the power to the motor, wherein the powered surgical tool has a pencil-grip configuration; and The plastic housing includes a controller configured to regulate the power drawn from the rechargeable battery module based on the movement of the lever.

69. The powered surgical tool of claim 68, further comprising a manual switch sensor configured to output a manual switch sensor signal based on the position of the lever, wherein the controller is configured to receive the manual switch sensor signal and adjust the power drawn from the rechargeable battery module based on the manual switch sensor signal.

70. The powered surgical tool of claim 69, wherein the manual switch sensor is further defined as a first manual switch sensor, and the manual switch sensor signal is further defined as a first manual switch sensor signal, the powered surgical tool further comprising a second manual switch sensor configured to output a second manual switch sensor signal based on the position of the lever, wherein the controller is configured to receive the second manual switch sensor signal and to regulate the power drawn from the rechargeable battery module based on the first manual switch sensor signal and the second manual switch sensor signal.

71. The powered surgical tool of claim 70, wherein the first manual switch sensor and the second manual switch sensor are respectively mounted on opposite surfaces of the printed circuit board, and the controller is disposed on the printed circuit board.

72. The powered surgical tool of claim 71, wherein the lever comprises an operating safety switch slidably mounted to the lever, a magnet mounted to the operating safety switch, and a lever extension movably coupled to the lever, wherein the manual switch sensor is a Hall effect sensor.

73. A powered surgical tool, comprising: A shell that defines the void; A circuit board, disposed in the gap of the housing, is used to adjust the operation of the electric motor; A rechargeable battery module is disposed within the gap; At least three motor pins are spaced apart from each other to define a motor pin array, the motor pin array extending through the housing and out of the gap to establish an electrical connection between the circuit board and the electric motor, wherein a hermetically sealed housing-terminal interface is defined by the housing and the at least three motor pins; A layout feature is provided around the at least three motor pins, and the layout feature defines multiple channels; and At least three wires, each of the three wires including a wire terminal connected to a first wire end of the at least three wires and the other end of the wire connected to the circuit board, each wire terminal including a first end portion and a second end portion opposite to the first end portion, the first end portion being connected to one of the at least three wires, and the second end portion being shaped to electrically engage one of the motor pins, each wire terminal being positioned within one of the channels of the layout feature.

74. The powered surgical tool of claim 73, wherein at least one of the at least three motor pins defines a longitudinal axis, and the circuit board defines a longitudinal axis, wherein the longitudinal axis of the at least one motor pin is parallel to the longitudinal axis of the circuit board.

75. The powered surgical tool of claim 74, wherein the at least three motor pins are further defined as at least six motor pins, and wherein the at least three wires are further defined as at least six wires.

76. The powered surgical tool of claim 75, wherein the at least six motor pins are positioned equidistant from the center of the array.

77. The powered surgical tool of claim 76, wherein the arrangement feature defines an edge portion that defines the plurality of channels and surrounds the at least three motor pins.

78. The powered surgical tool of claim 77, wherein the first end portion of the wire terminal is disposed inside the edge portion, and the second end portion of the wire terminal is disposed outside the edge portion.

79. The powered surgical tool of claim 78, wherein the wire terminal defines a bend of at least 70 degrees, and wherein the first end portion of the wire terminal is separated from the second end portion of the wire terminal by the bend.

80. The powered surgical tool of claim 79, wherein the plurality of channels includes a first channel and a second channel, wherein the first channel has a first depth and the second channel includes a second depth, the first depth being different from the second depth.

81. The powered surgical tool of claim 79, wherein the first end portion of at least one of the wire terminals defines a plurality of arms, the arms being crimped to engage the first wire terminal.

82. The powered surgical tool of claim 81, wherein the second end portion of the wire terminal defines a cylindrical gap surrounding the motor pin.

83. A powered surgical tool, comprising: Including the handheld component of the motor; A module housing configured to connect to one of the handheld device and the charging module, wherein each of the handheld device and the charging module is configured to generate a magnetic field; and Printed circuit board assembly, the printed circuit board assembly comprising: A digital Hall effect sensor configured to sense magnetic fields; A simulated Hall effect sensor configured to sense magnetic fields; and The controller is configured to: Operation in sleep mode, wherein the digital Hall effect sensor is activated and the analog Hall effect sensor is deactivated; and Operates in an active state, wherein the simulated Hall effect sensor is activated; The controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and The controller is configured to determine whether the module housing has been connected to one of the handheld device and the charging module based on the magnetic field sensed by the simulated Hall effect sensor.

84. The powered surgical tool of claim 83, wherein the module housing includes a rechargeable battery module, wherein the controller is disposed within the module housing, wherein the digital Hall effect sensor is configured to receive power from the rechargeable battery module in the sleep state, and wherein the analog Hall effect sensor is configured to receive power from the rechargeable battery in the active state.

85. The powered surgical tool according to claim 84, wherein, Compared to the digital Hall effect sensor in the sleep state, the analog Hall effect sensor in the active state receives a greater amount of power from the rechargeable battery.

86. The powered surgical tool according to any one of claims 83-85, wherein the controller is configured to: In response to determining that the module housing is connected to the handheld device, the module communicates with the handheld device using a first communication protocol; and In response to determining that the module housing is connected to the charging module, the second communication protocol is used to communicate with the charging module.

87. The powered surgical tool of claim 86, wherein the controller is configured to communicate using the first communication protocol at a first transmission speed, and wherein the controller is configured to communicate using the second communication protocol at a second transmission speed.

88. The powered surgical tool of claim 86, wherein the controller is configured to communicate using the first communication protocol via full-duplex transmission, and wherein the controller is configured to communicate using the second communication protocol via half-duplex transmission.

89. The powered surgical tool according to any one of claims 83-88, wherein the controller is configured to send communication signals to the handpiece based on determining that the module housing has been connected to the handpiece.

90. The powered surgical tool according to any one of claims 83-89, wherein the controller is configured to transmit a communication signal to the charging module based on determining that the module housing is connected to the charging module.

91. The powered surgical tool according to any one of claims 83-90, wherein the module housing is further configured to be coupled to a programming fixture, wherein the programming fixture is configured to generate a magnetic field, and wherein the controller is configured to determine whether the module housing is coupled to the programming fixture based on the magnetic field being sensed by the simulated Hall effect sensor.

92. The powered surgical tool of claim 91, wherein the controller is configured to receive communication signals from the programming fixture based on determining that the module housing is engaged with the programming fixture.

93. A system for identifying a device connected to a powered surgical tool, comprising: A handheld device configured to generate a magnetic field; A charging module configured to generate a magnetic field; and Powered surgical tools, the powered surgical tools comprising: Module housing, configured to connect with one of the handheld device and the charging module; and Printed circuit board assembly, the printed circuit board assembly comprising: A digital Hall effect sensor configured to sense magnetic fields; A simulated Hall effect sensor configured to sense magnetic fields; and The controller is configured to operate in both sleep and active states: During the sleep state, the digital Hall effect sensor is activated, and the analog Hall effect sensor is deactivated; and In the activated state, the simulated Hall effect sensor is activated; The controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and The controller is configured to determine whether the module housing has been connected to one of the handheld device and the charging module based on the magnetic field being sensed by a simulated Hall effect sensor.

94. The system of claim 93, wherein the analog Hall effect sensor is further defined as a first analog Hall effect sensor, and wherein the printed circuit board assembly further includes a second analog Hall effect sensor and a third analog Hall effect sensor.

95. The system according to claim 94, wherein: The handheld device also includes a motor, which includes a first rotor magnet and a second rotor magnet, each configured to generate a magnetic field to cause the motor to rotate. The first simulated Hall effect sensor, the second simulated Hall effect sensor, and the third simulated Hall effect sensor are each configured to sense the magnetic field generated by the first rotor magnet and the second rotor magnet; The controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing the magnetic field generated by the first rotor magnet and the second rotor magnet; and The controller is configured to determine that the module housing has been connected to the handheld device based on the magnetic fields generated by the first and second rotor magnets sensed by the first, second, and third analog Hall effect sensors.

96. The system of claim 93, further comprising a programming fixture, the programming fixture including a magnet configured to generate a first magnetic field, wherein: The charging module includes a magnet configured to generate a second magnetic field; The simulated Hall effect sensor is configured to sense the magnetic field by sensing the magnitude of the magnetic field; and The positions of the magnets in the programming fixture and the charging module are selected such that the magnitude of the first magnetic field sensed by the simulated Hall effect sensor is different from the magnitude of the second magnetic field sensed by the simulated Hall effect sensor.

97. The system of claim 93, further comprising a programming fixture, the programming fixture including a magnet configured to generate a first magnetic field, wherein: The charging module includes a magnet configured to generate a second magnetic field; The simulated Hall effect sensor is configured to sense the magnetic field by sensing the polarity of the magnetic field; and The polarity of the magnet in the programming fixture and the polarity of the magnet in the charging module are selected such that the polarity of the first magnetic field sensed by the simulated Hall effect sensor is different from the polarity of the second magnetic field sensed by the simulated Hall effect sensor.

98. A powered surgical tool, comprising: Including the first hand-held component of the motor; Including the second hand-held component of the motor; A module housing configured to be coupled to one of a first handheld component and a second handheld component, each of which is configured to generate a magnetic field; as well as Printed circuit board assembly, the printed circuit board assembly comprising: A digital Hall effect sensor configured to sense magnetic fields; A simulated Hall effect sensor configured to sense magnetic fields; and The controller is configured to operate in both sleep and active states: During the sleep state, the digital Hall effect sensor is activated, and the analog Hall effect sensor is deactivated; and In the activated state, the simulated Hall effect sensor is activated; The controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and The controller is configured to determine whether the module housing has been connected to one of the handheld device and the charging module based on the magnetic field being sensed by a simulated Hall effect sensor.

99. A system for identifying a device connected to a powered surgical tool, comprising: A handheld device configured to generate a magnetic field; A charging module is connected to a charging adapter configured to generate a magnetic field; and Powered surgical tools, the powered surgical tools comprising: Module housing, configured to connect with one of the handheld device and the charging module; and Printed circuit board assembly, the printed circuit board assembly comprising: A digital Hall effect sensor configured to sense magnetic fields; A simulated Hall effect sensor configured to sense magnetic fields; and The controller is configured to operate in both sleep and active states: During the sleep state, the digital Hall effect sensor is activated, and the analog Hall effect sensor is deactivated; and In the activated state, the simulated Hall effect sensor is activated; The controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor sensing a magnetic field; and The controller is configured to determine whether the module housing has been connected to one of the handheld device and the charging adapter based on the magnetic field being sensed by a simulated Hall effect sensor.

100. A charging system for charging a rechargeable battery module of a powered surgical tool, the powered surgical tool including a module housing configured to receive a handpiece, the charging system comprising: Charger including recessed slots; and An adapter, the adapter comprising: A charger protrusion configured to be received by the recess, wherein the recess includes a surface facing a first direction; and A module protrusion configured to be received by the module housing to allow the charger to provide power to the rechargeable battery module via the adapter, wherein the module protrusion extends in a direction different from the first direction.

101. The charging system of claim 100, wherein the charger includes two recesses, and wherein the adapter includes two charger protrusions configured to engage the two recesses.

102. The charging system of claim 101, wherein the adapter includes two module protrusions.

103. The charging system according to claim 102, wherein: Each groove includes its width; Each of the module protrusions includes a width; and The sum of the widths of the module protrusions is less than the width of the groove.

104. The charging system of claim 103, wherein the two charger protrusions of the adapter are disposed along a first direction, and wherein the two module protrusions are disposed along a second direction different from the first direction.

105. A charging system for charging a rechargeable battery module of a pencil-grip type first powered surgical tool and a pistol-grip type second powered surgical tool, wherein the first powered surgical tool and the second powered surgical tool each include a module housing configured to receive a handheld component, the charging system comprising: Charger including recessed slots; and An adapter, the adapter comprising: A charger protrusion configured to be received by the recess; and Module protrusion, the module protrusion being configured as follows: Received by the module housing of the first powered surgical tool, allowing the charger to supply power to the rechargeable battery module of the first powered surgical tool via the adapter; and Received by the module housing of the second powered surgical tool to allow the charger to provide power to the rechargeable battery module of the second powered surgical tool via the adapter.

106. The charging system of claim 105, wherein the module protrusion comprises: A first latch, configured to engage an interface of the module housing of the first powered surgical tool; and A second latch is configured to engage the interface of the module housing of the second powered surgical tool.

107. The charging system of claim 106, wherein the module protrusion comprises: The first part is shaped to be received by the module housing of the first powered surgical tool; and The second part is shaped to be received by the module housing of the second powered surgical tool.

108. The charging system according to claim 107, wherein: The module housing of the first powered surgical tool includes a first radius; The module housing of the second powered surgical tool includes a second radius different from the first radius; The first portion of the module protrusion includes a cylindrical shape sized to be received by the module housing of the first powered surgical tool; and The second portion of the module protrusion includes a cylindrical shape whose dimensions are set to be received by the module housing of the second powered surgical tool.

109. The charging system of claim 107, wherein the module protrusion comprises: A first latch is disposed on the first portion, the first latch being configured to engage an interface of the module housing of the first powered surgical tool; and A second latch is disposed on the second portion, the second latch being configured to engage the interface of the module housing of the second powered surgical tool.

110. A charging system, comprising: Charger including recessed slots; An adapter, the adapter comprising: A charger protrusion configured to be received by the recess; Module protrusions; and A magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; A first powered surgical tool, the first powered surgical tool comprising: A first module housing is configured to receive the module protrusion, the first module housing including a first end and a second end; A first Hall sensor is located at a first distance from the first end of the module housing; and A first controller is configured to transition from a sleep state to an active state based on a magnetic field sensed by the first Hall sensor, wherein the first controller is configured to communicate with the charger when the first controller is in the active state; and A second powered surgical tool, comprising: A second module housing, configured to receive the module protrusion, the second module housing including a first end and a second end; A second Hall sensor is located at a second distance from the first end of the second module housing, the second distance being different from the first distance; and A second controller is configured to transition from a sleep state to an active state based on a magnetic field sensed by the second Hall sensor, wherein the second controller is configured to communicate with the charger when the second controller is in the active state.

111. The charging system of claim 110, wherein the first Hall sensor is configured to sense a magnetic field generated by the magnet in response to the first module housing receiving the module protrusion.

112. The charging system of claim 111, wherein the second Hall sensor is configured to sense the magnetic field generated by the magnet in response to the second module housing receiving the module protrusion.

113. A charging system, comprising: charger; A battery configured to receive power from the charger in response to contact with the charger; An adapter, the adapter comprising: A charger protrusion configured to contact the charger; Module protrusion; and A magnet disposed on the module protrusion, the magnet being configured to generate a magnetic field; and Powered surgical tools, the powered surgical tools comprising: A module housing configured to receive the module protrusion; Hall effect sensors; and A controller configured to transition from a sleep state to an active state based on the Hall sensor sensing a magnetic field, wherein the controller is configured to communicate with the charger when the controller is in the active state.

114. The charging system of claim 113, wherein the controller is configured to communicate using a first communication protocol, and wherein the charger is configured to communicate using a second communication protocol, and wherein the adapter is configured to convert one of the first communication protocol and the second communication protocol to the other of the second communication protocol and the first communication protocol, such that the controller is configured to communicate with the charger via the adapter.

115. The charging system of claim 114, wherein the charger includes a charger power terminal and a charger communication terminal, wherein the charger protrusion includes an adapter communication contact configured to contact the charger communication terminal and an adapter power contact configured to contact the charger power terminal, wherein the module protrusion includes a first adapter communication terminal and a second adapter communication terminal communicating with the adapter communication contact, and wherein the first adapter communication terminal and the second adapter communication terminal are shorted to each other, such that the controller is configured to communicate with the charger via the adapter.

116. The charging system of claim 115, wherein the controller is configured to communicate using the first communication protocol via full-duplex transmission, and wherein the charger is configured to communicate using the second communication protocol via half-duplex transmission; and wherein the adapter is configured to convert the second communication protocol to the first communication protocol by converting half-duplex transmission to full-duplex transmission.

117. A surgical handpiece for coupling to a battery and a control module, the surgical handpiece comprising: case; An electric motor disposed within the housing and including a rotor, the rotor including an output shaft defining a longitudinal axis, the output shaft being coupled to the electric motor at a first end and configured to be coupled to a surgical instrument at a second end, wherein the output shaft defines an inner cavity centered on the longitudinal axis of the output shaft; A cannula, which is partially disposed within the lumen and extends from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; A sealing plug, which is connected to the housing and configured to prevent liquid from entering the interior of the surgical handpiece, wherein the cannula passes through the sealing plug; A seal, the seal being disposed around the outside of the sleeve; and Multiple terminals extend through the sealing plug.

118. The surgical handpiece of claim 117, wherein the second distal end includes a tool connector.

119. The surgical handpiece according to any one of claims 117 and 118, wherein the cavity centered on the longitudinal axis of the output shaft is a first cavity; The seal comprises a cylindrical shape having a second inner cavity; and The sleeve is disposed within the second inner cavity.

120. The surgical handpiece of claim 119, wherein the seal includes a first sealing surface on the cylindrical end surface, wherein the end surface abuts against a mating surface on the sealing plug.

121. The surgical handpiece of claim 120, wherein the seal includes a second sealing surface, the second sealing surface including an annular surface on the inner diameter of the seal, the annular surface abutting against the outer surface of the sleeve.

122. The surgical handpiece according to any one of claims 117-121, wherein the sealing plug comprises a polymer.

123. The surgical handheld device according to claim 122, wherein, The housing includes an internal structure insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece; and The sealing plug is press-fitted within the inner diameter of the internal structure insert.

124. The surgical handpiece of claim 123, further comprising a port stop disposed around the exterior of the internal structure insert and the sealing plug, wherein the port stop is configured to retain the sealing plug within the inner diameter of the internal structure insert.

125. The surgical handpiece according to any one of claims 117-124, wherein the seal is configured to contact the sleeve flange.

126. A powered surgical tool, comprising: Surgical handpiece, the surgical handpiece comprising: case; An electric motor disposed within the housing and including a rotor, the rotor including an output shaft defining a longitudinal axis, the output shaft being coupled to the electric motor at a first end and configured to be attached to a surgical instrument at a second end, wherein the output shaft defines an inner cavity centered on the longitudinal axis of the output shaft; A cannula, which is partially disposed within the lumen and extends from a first proximal end of the surgical handpiece to a second distal end of the surgical handpiece, the cannula defining a cannula flange; A sealing plug connected to the housing, wherein the sleeve passes through the sealing plug; A seal disposed around the outside of the sleeve; and Multiple terminals extending through the sealing plug; and The battery and control module include a recess configured to receive the surgical handpiece.

127. The powered surgical tool of claim 126, wherein the battery and control module further includes a cannula access point configured to provide external access to the cannula within the first proximal end of the surgical handpiece.

128. The powered surgical tool according to any one of claims 126 and 127, wherein the second distal end includes a tool connector.

129. The powered surgical tool according to any one of claims 126-128, wherein the seal comprises a cylindrical shape having a hollow portion; and The sleeve is disposed within the hollow portion of the seal.

130. The powered surgical tool of claim 129, wherein the seal includes a first sealing surface on the end surface of the cylindrical shape, the end surface abutting a mating surface on the sealing plug; and The seal includes a second sealing surface, which includes an annular portion on the inner diameter of the seal that abuts against the outer surface of the sleeve.

131. The powered surgical tool according to any one of claims 126-130, wherein the sealing plug comprises a polymer.

132. The powered surgical tool of claim 131, wherein the housing includes an internal structure insert disposed within the housing and comprising an inner diameter at the first proximal end of the surgical handle; and in, The sealing plug is press-fitted into the inner diameter of the internal structure insert.

133. The powered surgical tool of claim 132, further comprising a port stop disposed around the exterior of the internal structure insert and the sealing plug, wherein the port stop is configured to retain the sealing plug within the inner diameter of the internal structure insert.

134. The powered surgical tool according to any one of claims 126-130, wherein the seal is configured to contact the sleeve flange.

135. The powered surgical tool according to any one of claims 126-134, wherein the battery and control module define a pistol grip.

136. A powered surgical tool, comprising: The battery and control module include: A sealed housing assembly, the sealed housing assembly comprising: A printed circuit board including at least one trigger sensor; Multiple housings, the multiple housings being hermetically connected together and configured to enclose the printed circuit board and the at least one trigger sensor therein; and At least one trigger cavity configured to receive a trigger, wherein the at least one trigger sensor is disposed adjacent to the at least one trigger cavity; and At least one trigger is mounted to the battery and control module, and the at least one trigger cavity includes a rod portion configured to engage with the at least one trigger cavity, wherein the rod portion includes at least one magnet configured to interact with the at least one trigger sensor.

137. The powered surgical tool of claim 136, wherein the at least one trigger lumen includes a trigger ventilation incision formed in the wall of the at least one trigger lumen; The trigger vent cutout is formed in the surface of the wall without compromising the seal of the sealed housing assembly; and The trigger vent is configured to allow air to be released from behind the at least one trigger when the at least one trigger is pressed or installed.

138. The powered surgical tool according to any one of claims 136 and 137, wherein the at least one trigger is held within the cavity of the at least one trigger by a screw and a front plate; and The screws and the front plate allow the at least one trigger to be replaced without compromising the seal of the sealed housing assembly.

139. The powered surgical tool according to any one of claims 136-138, wherein the sealed housing assembly comprises two trigger cavities; and It also includes two triggers.

140. The powered surgical tool according to any one of claims 136-139, wherein the sealed housing assembly further comprises a battery, the battery comprising at least one battery cell.

141. The powered surgical tool according to any one of claims 136-140, wherein the sealed housing assembly further comprises a handpiece cavity configured to receive a handpiece, the handpiece including a modular motor configured to provide power to a surgical end effector.

142. The powered surgical tool according to any one of claims 136-141, wherein, The at least one trigger sensor is configured to detect the at least one magnet through one of the plurality of housings.

143. The powered surgical tool according to any one of claims 136-142, wherein the plurality of housings sealed together are welded together by one of a vibration welding process or a laser process.

144. A method of operating a powered surgical tool, comprising the following steps: A battery and control module are provided, comprising a sealed housing assembly encapsulating a printed circuit board including at least one trigger sensor and including at least one trigger cavity configured to receive a trigger. as well as At least one trigger is mounted into the trigger cavity, the trigger including a rod portion having at least one magnet configured to interact with the trigger sensor without compromising the seal of the sealed housing assembly.

145. A method for repairing a powered surgical tool, comprising the following steps: A battery and control module are provided, comprising a sealed housing assembly encapsulating a printed circuit board including at least one trigger sensor, the battery and control module further comprising a trigger having a magnet; as well as The trigger is removed from the battery and control module without compromising the seal of the sealed housing assembly.

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