Surgical system including a battery and control module

Abstract

A powered surgical instrument 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. A rechargeable battery module is disposed within the void space. A controller is configured to regulate power drawn from the rechargeable battery module based on user input.

Description

[Background technology]

[0001] Modular handheld powered surgical instruments are common in modern operating rooms. Exemplary powered surgical instruments include burrs, drills, saws, and shavers. Modular handheld powered surgical instruments typically include a handpiece component that includes a motor of sufficient size to meet the demands of a surgical procedure, such as resecting cortical bone and other hardened anatomical structures. Modular handheld powered surgical instruments also typically include a device housing configured to couple to and provide power to the motor of the handpiece component. As the applications of modular handheld powered surgical instruments continue to expand, it is important that the modular handheld powered surgical instruments include a device housing that can accommodate and identify a wide variety of devices. Summary of the Invention

[0002] Therefore, there is a need in the art for a handheld powered surgical tool that can identify and provide power to a variety of devices.

[0003] In a first aspect, a powered surgical tool is provided, the powered surgical tool comprising: a handpiece including a motor and an instrument coupler, the handpiece defining at least one of a rail and a slot, the handpiece further defining a receiving surface; a battery and control module, a device housing including the other of the rail and the slot, the rail and the slot configured such that the rail is slidable within the slot to enable coupling of the handpiece with the battery and control module, the device housing further defining a void space; a rechargeable battery module disposed within the void 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 comprising a motor sensor configured to output a motor sensor signal representative of a state of the motor; and at least three conductive terminals extending through the device housing to establish 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 comprising: a handpiece including a motor and an instrument coupler, the handpiece defining a cannulation; a battery and control module, the battery and control module including a device housing defining a void space, a rechargeable battery module disposed within the void 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 representative of a state of the motor; and at least three conductive terminals extending through the device housing to establish an electrical connection between the printed circuit board assembly and the handpiece, the battery and control module being devoid of a cannulation.

[0005] In a third aspect, a surgical handpiece coupled to a battery and control module is provided, the surgical handpiece including a housing, an instrument coupler, an electric motor disposed within the housing, a rotor defining an axis, the rotor coupled to the electric motor and the instrument coupler, a rigid circuit board including a controller, the rigid circuit board 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 coupled to a battery and a control module is provided, the surgical handpiece including: a housing; an instrument coupler; an electric motor disposed within the housing; a rotor defining an axis, the rotor coupled to the electric motor and the instrument coupler; a circuit board including a controller, the circuit board 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 comprising: a handpiece including a motor; a battery and control module including: a device housing having a recess that removably receives the handpiece, the device housing defining a void space; a rechargeable battery module disposed within the void space; a first printed circuit board disposed within the void space and having a rigidity; a second printed circuit board disposed within the void space and having a rigidity, the second printed circuit board coupled to the first printed circuit board, the second printed circuit board and the first printed circuit board being arranged in a stacked configuration, and a controller configured to adjust power drawn from the rechargeable battery module based on user input, the controller being attached 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 comprising: a handpiece including a motor; a battery and control module, the battery and control module including: a device housing having a recess that removably receives the handpiece, the device housing defining a void space; a rechargeable battery module disposed within the void space; a printed circuit board assembly disposed within 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 adjust power drawn from the rechargeable battery module based on user input, the controller being attached to the printed circuit board assembly.

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

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

[0011] In a ninth aspect, a powered surgical tool is provided, the powered surgical tool comprising: a housing defining a cavity; a circuit board disposed within the cavity of the housing for controlling operation of an electric motor; a rechargeable battery module disposed within the cavity; at least three motor pins spaced apart from one another to define an array of motor pins extending through the housing and out of the cavity to establish electrical connections between the circuit board and the electric motor, the at least three motor pins defining a hermetically sealed housing-terminal interface defined by the housing and the at least three motor pins; and a routing mechanism disposed around the at least three motor pins. the routing mechanism defining a plurality of 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 another end of the wire connected to the circuit board, each of the wire terminals including a first end and a second end opposite the first end, the first end connected to one of the at least three wires and the second end configured to electrically engage one of the motor pins, each of the wire terminals positioned within one of the channels of the routing mechanism.

[0012] In a tenth aspect, a powered surgical tool is provided comprising: a handpiece including a motor; a module housing configured to couple to one of the handpiece and a charging module, each of the handpiece and the charging module 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 in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive, and an active state in which the analog Hall effect sensor is active, the controller configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting the magnetic field, and the controller configured to determine whether the module housing is coupled to one of the handpiece and the charging module based on the magnetic field sensed by the analog Hall effect sensor.

[0013] In an eleventh aspect, a system for identifying a device coupled to a powered surgical tool is provided, the system comprising: a handpiece configured to generate a magnetic field; a charging module configured to generate the magnetic field; a powered surgical tool comprising: a module housing configured to couple to one of the handpiece and the charging module; a printed circuit board assembly including: a digital Hall effect sensor configured to detect the magnetic field; an analog Hall effect sensor configured to detect the magnetic field; and a controller configured to operate in a sleep state in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive, and an active state in which the analog Hall effect sensor is active, the controller configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting the magnetic field, and the controller configured to determine whether the module housing is coupled to one of the handpiece and the charging module based on the magnetic field detected by the analog Hall effect sensor.

[0014] In a twelfth aspect, a powered surgical tool is provided, the powered surgical tool comprising: a first handpiece including a motor; a second handpiece including a motor; a module housing configured to couple to one of the first handpiece and the second handpiece, 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 detect the magnetic field; an analog Hall effect sensor configured to detect the magnetic field; and a controller configured to operate in a sleep state in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive, and an active state in which the analog Hall effect sensor is active, the controller configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting the magnetic field, and the controller configured to determine whether the module housing is coupled to one of the handpiece and the charging module based on the magnetic field detected by the analog Hall effect sensor.

[0015] In a thirteenth aspect, a system for identifying a device coupled to a powered surgical tool is provided, the system comprising: a handpiece configured to generate a magnetic field; a charging module coupled to a charging adapter, the charging adapter configured to generate the magnetic field; a powered surgical tool, the powered surgical tool comprising: a module housing configured to couple with one of the handpiece and the charging module; a printed circuit board assembly, the printed circuit board assembly including: a digital Hall effect sensor configured to detect the magnetic field; an analog Hall effect sensor configured to detect the magnetic field; and a controller configured to operate in a sleep state in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive, and an active state in which the analog Hall effect sensor is active, the controller configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting the magnetic field, and the controller configured to determine whether the module housing is coupled with one of the handpiece and the charging module based on the magnetic field detected by the analog Hall effect sensor.

[0016] In a fourteenth aspect, a surgical handpiece coupled to a battery and a control module is provided, the surgical handpiece comprising: a housing; an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft configured to be coupled at a first end to the electric motor and at a second end to a surgical instrument, the output shaft defining a lumen centered about the longitudinal axis of the output shaft; a cannula disposed partially within the lumen 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, the cannula passing through the sealing plug; a seal disposed around an exterior of the cannula; and a plurality of terminals extending through the sealing plug.

[0017] In a fifteenth embodiment, a powered surgical instrument is provided. The powered surgical instrument comprises a surgical handpiece including a housing, an electric motor disposed within the housing and including a rotor including an output shaft defining a longitudinal axis, the output shaft configured to be coupled to the electric motor at a first end and attached to a surgical instrument at a second end, the output shaft defining a lumen centered on the longitudinal axis of the output shaft, a cannula disposed partially within the lumen 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, the cannula penetrating the sealing plug, and a seal disposed around the exterior of the cannula. The powered surgical instrument further comprises a plurality of terminals extending through the sealing plug and a battery and control module including a module lumen configured to receive the surgical handpiece.

[0018] In a sixteenth aspect, there is provided 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: a charger including a recess; an adapter including a charger protrusion configured to be received in the recess, the recess including a surface facing a first direction; and a module protrusion configured to be received in the module housing to enable the charger to provide power to the rechargeable battery module via the adapter, the module protrusion extending 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 of a pencil grip type and a rechargeable battery module of a second powered surgical tool of a pistol grip type, the first powered surgical tool and the second powered surgical tool each including a module housing configured to receive a handpiece. The charging system includes a charger including a recess, an adapter including a charger protrusion configured to be received in the recess, and a module protrusion configured to be received in the module housing of the first powered surgical tool to enable the charger to provide power to the rechargeable battery module of the first powered surgical tool via the adapter, and in the module housing of the second powered surgical tool to enable 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 including: a charger including a recess; an adapter, the charger protrusion configured to be received in the recess; a module protrusion; and a magnet disposed on the module protrusion, the magnet configured to generate a magnetic field; a first powered surgical instrument, the 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 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 detecting the magnetic field, the first controller being configured to transition from a sleep state to an active state when the first controller is in the active state. and a first controller configured to communicate with a charger; and a second powered surgical instrument including: a second module housing configured to receive a module protrusion, the second module housing including a first end and a second end; a second Hall sensor located 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 detecting a magnetic field, the second controller being configured to communicate with a charger when the second controller is in the active state.

[0021] In a nineteenth aspect, a charging system is provided comprising: a charger; a battery configured to receive power from the charger in response to contacting 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 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 detecting the magnetic field, the controller 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 includes a sealed housing assembly including a printed circuit board including at least one trigger sensor, a plurality of housings hermetically joined to one another and configured to house the printed circuit board and the at least one trigger sensor therein, and at least one trigger lumen configured to receive a trigger, the at least one trigger sensor being disposed proximate to the at least one trigger lumen. The powered surgical tool further includes at least one trigger mounted in the battery and control module within the at least one trigger lumen, the at least one trigger including a stem portion configured to engage with the at least one trigger lumen, the stem portion including 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 providing a battery and control module including a sealed housing assembly, the housing assembly enclosing a printed circuit board including at least one trigger sensor and at least one trigger lumen configured to receive the trigger. The method further includes installing at least one trigger within the trigger lumen, the trigger including a stem portion having at least one magnet configured to interact with the trigger sensor without compromising the hermeticity of the sealed housing assembly.

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

[0025] In some embodiments, the handpiece defines a cannula and the device housing is non-cannulated. In some embodiments, the surgical handpiece defines a longitudinal axis and the surgical handpiece defines a cannula surrounding the longitudinal axis. In some embodiments, the rigid circuit board defines an aperture, the aperture surrounding the cannula. In some embodiments, the aperture and the cannula are coaxial. In some embodiments, the battery and control module includes a safety vent. In some embodiments, the battery and control module further comprises a plurality of support ribs and a board mount, the board mount including a plurality of wings for engaging the support ribs. In some embodiments, 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. In some embodiments, the battery and control module further comprises a board mount, the board mount including one of a set of notches or a set of protrusions, and the device housing defining the other of the set of notches or the set of protrusions, the set of protrusions engaging the set of notches to prevent the board mount from moving in more than one degree of freedom relative to the device housing. In some embodiments, the battery and control module further comprises a board mount, the board mount including one of a set of notches or a set of protrusions, and the device housing defining the other of the set of notches or the set of protrusions, the set of protrusions engaging the set of notches to prevent the rigid portion of the printed circuit board assembly from moving in more than one degree of freedom relative to the device housing. In some embodiments, the set of notches and / or the set of protrusions are positioned in an arcuate arrangement relative to each other. In some embodiments, the substrate mount includes a set of protrusions, each of the set of protrusions defining a receiving portion for securing one of the plurality of motor control sensors.In some embodiments, the board mount comprises a body portion and a flange, the 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 comprises a plurality of spacers, the plurality of spacers being disposed between the first printed circuit board and the second printed circuit board. In some embodiments, each of the plurality of spacers defines a hole, and the battery and control module comprises a plurality of fasteners disposed to extend through the first printed circuit board, at least one hole in the plurality of spacers, and the second printed circuit board. In some embodiments, the board mount defines a plurality of mounting holes, each of the plurality of mounting holes including a threaded insert. In some embodiments, the battery and control module comprises a latch assembly including a locking member and a biasing member, the biasing member being positioned to bias the locking member toward the receiving 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, the notches defining a series of notch peaks and notch valleys, with the innermost surfaces of the notch peaks being farther from the motor magnets than the innermost surfaces of the notch valleys. In some embodiments, the sensor is further defined as a first set of sensors, the first set of sensors being 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 instrument further includes a second set of sensors, the second set of sensors being analog Hall effect sensors. In some embodiments, the controller is configured to energize the first terminals based on the first set of sensors, and the controller is configured to commutate the motor based on the second set of sensors. In some embodiments, the sensors in the first set of sensors are aligned with one another. In some embodiments, the sensors in the second set of sensors are aligned with one another. In some embodiments, the sensors in the first set are axially offset from the sensors in the second set. In some embodiments, the motor includes a motor rotor, laminations surrounding the motor rotor, and a plurality of magnets surrounding the rotor, some of the plurality of magnets extending axially beyond the laminations.

[0027] In some embodiments, the controller is configured to transition between a sleep state and an active state, and the powered surgical tool is configured to transition the controller from the sleep state to the active state based on the sensor signal. In some embodiments, the powered surgical tool further comprises a second terminal, the second terminal being energized while the controller is in the sleep state and the active state. In some embodiments, the controller is in the sleep state and the powered surgical tool has a current consumption of less than 5 mA.

[0028] In some embodiments, the battery and control module further comprises a third printed circuit board, the third printed circuit board connected to one of the first printed circuit board and the second printed circuit board via conductors, the third printed circuit board comprising at least three conductive terminals extending at least partially through the device housing to establish an electrical connection between the third printed circuit board and the hand piece. In some embodiments, the hand piece comprises a memory device electrically connected to at least one of the plurality of terminals. In some embodiments, the hand piece comprises 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 printed circuit board. In some embodiments, the conductor is further defined as a flexible circuit. In some embodiments, the first printed circuit board has a larger surface area than the second circuit board. In some embodiments, when the hand piece is coupled to the battery and control module, the first printed circuit board is further from the motor than the second circuit board. In some embodiments, the first printed circuit board and the second printed circuit board are interconnected by a board header. In some embodiments, the second printed circuit board includes two major sides, and the board mount contacts only one of the two major sides. In some embodiments, the second printed circuit board includes at least four minor sides, and the board mount contacts no more than two sides of the second printed circuit board. In some embodiments, the second printed circuit board includes at least four sides, and the board mount does not contact any 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 handpiece includes a memory device and data terminals, the data terminals being in electrical communication with the memory device and configured to connect with second terminals of the control module when the handpiece is received in the recess.

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

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

[0031] In some embodiments, the powered surgical instrument further comprises a handpiece including a motor, the plastic housing defining a recess for removably receiving the handpiece, the plastic housing defining a void space, a printed circuit board disposed within the void space, and a rechargeable battery module disposed within the void space, the lever configured to receive input from a user to cause power to be drawn from the rechargeable battery module and provided to the motor, the powered surgical instrument having a pencil grip configuration, the plastic housing comprising a controller configured to adjust power drawn from the rechargeable battery module based on movement of the lever. In some embodiments, the powered surgical instrument further comprises a handswitch sensor configured to output a handswitch sensor signal based on a position of the lever, the controller configured to receive the handswitch sensor signal and adjust power drawn from the rechargeable battery module based on the handswitch sensor signal. In some embodiments, the handswitch sensor is further defined as a first handswitch sensor, and the handswitch sensor signal is further defined as a first handswitch sensor signal, and the powered surgical instrument further includes a second handswitch sensor configured to output a second handswitch sensor signal based on a position of the lever, and the controller is configured to receive the second handswitch sensor signal and adjust power drawn from the rechargeable battery module based on the first handswitch sensor signal and the second handswitch sensor signal. In some embodiments, the first handswitch sensor and the second handswitch sensor 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 a run-safe switch slidably mounted to the lever, a magnet is attached to the run-safe switch, a lever extension is movably coupled to the lever, and the hand switch sensor is a Hall effect sensor.

[0032] In some embodiments, the powered surgical instrument further includes a torsion spring including a coil, a first leg, and a second leg, the first leg and the second leg extending from opposite ends of the coil, and the coil surrounding the first pin.

[0033] In some embodiments, the routing feature defines a rim, the rim defining a plurality of channels, the rim surrounding at least three motor pins. In some embodiments, a first end of the wire terminal is disposed inside the rim and a second end of the wire terminal is disposed outside the rim. In some embodiments, the wire terminal defines a bend of at least 70 degrees, the first end of the wire terminal being separated from the second end of the wire terminal by the bend. In some embodiments, the plurality of channels includes a first channel and a second channel, the first channel having a first depth and the second channel having a second depth, the first depth being different from the second depth. In some embodiments, the first end of at least one of the wire terminals defines a plurality of arms, the arms being crimped to engage the first wire end. In some embodiments, the second end of the wire terminal defines a cylindrical cavity, the cylindrical cavity being disposed around the motor pin.

[0034] In some embodiments, the control module is further defined as a battery and control module, and the battery and control module further comprises a rechargeable battery module. In some embodiments, the powered surgical instrument comprises a rechargeable battery module, and the digital Hall effect sensor is configured to receive power from the rechargeable battery module in a sleep state, and the analog Hall effect sensor is configured to receive power from the rechargeable battery in an active state. In some embodiments, the analog Hall effect sensor receives more power from the rechargeable battery in an active state than the digital Hall effect sensor receives in a sleep state.

[0035] In some embodiments, the controller is configured to communicate with the handpiece using a first communication protocol in response to determining that the module housing is coupled to the handpiece, and to communicate with the charging module using a second communication protocol in response to determining that the module housing is coupled to the charging module. In some embodiments, the controller is configured to communicate by communicating at a first transmission rate using the first communication protocol, and the controller is configured to communicate by communicating at a second transmission rate using the second communication protocol. In some embodiments, the controller is configured to communicate using the first communication protocol by communicating using full-duplex transmission, and the controller is configured to communicate using the second communication protocol by communicating using half-duplex transmission.

[0036] In some embodiments, the controller is configured to send a communication signal to the handpiece based on determining that the module housing is coupled to the handpiece. In some embodiments, the controller is configured to send a communication signal to the charging module based on determining that the module housing is coupled to the charging module. In some embodiments, the controller is configured to receive a communication signal from the programming tool based on determining that the module housing is coupled to the programming tool.

[0037] In some embodiments, the module housing is further configured to couple to a programming fixture, the programming fixture being configured to generate a magnetic field, and the controller being configured to determine whether the module housing is coupled to the programming fixture based on the magnetic field sensed by the analog Hall effect sensor.

[0038] In some embodiments, the analog Hall effect sensor is further defined as a first analog Hall effect sensor, and the printed circuit board assembly further includes a second analog Hall effect sensor and a third analog Hall effect sensor. In some embodiments, the handpiece further includes a motor including a first rotor magnet and a second rotor magnet, each of the first rotor magnet and the second rotor magnet configured to generate a magnetic field to cause rotation of the motor; the first analog Hall effect sensor, the second analog Hall effect sensor, and the third analog Hall effect sensor configured to detect the magnetic fields generated by the first rotor magnet and the second rotor magnet, respectively; the controller is configured to transition from a sleep state to an active state based on the digital Hall effect sensor detecting the magnetic fields generated by the first rotor magnet and the second rotor magnet; and the controller is configured to determine that the module housing is coupled to the handpiece based on the first analog Hall effect sensor, the second analog Hall effect sensor, and the third analog Hall effect sensor detecting the magnetic fields generated by the first rotor magnet and the second rotor magnet.

[0039] In some embodiments, the system further includes a programming fixture including a magnet configured to generate a first magnetic field, the charging module including a magnet configured to generate a second magnetic field, the analog Hall effect sensor configured to sense the magnetic field by detecting the magnitude of the magnetic field, and the position of the magnet in the programming fixture and the position of the magnet in the charging module are selected such that the magnitude of the first magnetic field sensed by the analog Hall effect sensor is different from the magnitude of the second magnetic field sensed by the analog Hall effect sensor.

[0040] In some embodiments, the system further comprises a programming fixture including a magnet configured to generate a first magnetic field, the charging module including a magnet configured to generate a second magnetic field, the analog Hall effect sensor configured to sense the magnetic field by sensing the polarity of the magnetic field, the polarity of the programming fixture magnet and the polarity of the charging module magnet being selected such that the polarity of the first magnetic field sensed by the analog Hall effect sensor is different from the polarity of the second magnetic field sensed by the analog Hall effect sensor. In some embodiments, the system further comprises a programming fixture including a magnet configured to generate a first magnetic field, the charging module including a magnet configured to generate a second magnetic field, the analog Hall effect sensor configured to sense the magnetic field by sensing the polarity of the magnetic field, the polarity of the programming fixture magnet and the polarity of the charging module magnet being selected such that the polarity of the first magnetic field sensed by the analog Hall effect sensor is different from the polarity of the second magnetic field sensed by the analog Hall effect sensor.

[0041] In some embodiments, the charger includes two recesses and the adapter includes two charger protrusions configured to engage with 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 module protrusion widths is less than the width of the recess. In some embodiments, the two charger protrusions of the adapter are arranged along a first direction and the two module protrusions are arranged 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 the module housing of a first powered surgical tool and a second latch configured to engage an interface of the module housing of a second powered surgical tool. In some embodiments, the module protrusion includes a first portion shaped to be received in the module housing of the first powered surgical tool and a second portion shaped to be received in the module housing of the second powered surgical tool. In some embodiments, the module housing of the first powered surgical tool includes a first radius and the module housing of the second powered surgical tool includes a second radius different from the first radius, and the first portion of the module protrusion includes a cylindrical shape sized to be received in 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 in the module housing of the second powered surgical tool. In some embodiments, the module projection includes a first latch disposed on the first portion, the first latch configured to engage with an interface of the module housing of the first powered surgical tool, and a second latch disposed on the second portion, the second latch configured to engage with an interface of the module housing of the second powered surgical tool.

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

[0044] In some embodiments, the controller is configured to communicate using a first communication protocol, the charger is configured to communicate using a second communication protocol, and 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. In some embodiments, the charger includes charger power terminals and charger communication terminals, the charger protrusion includes adapter communication contacts configured to contact the charger communication terminals and adapter power contacts configured to contact the charger power terminals, the module protrusion includes first and second adapter communication terminals in communication with the adapter communication contacts, and the first and second adapter communication terminals are shorted to each other such that the controller is configured to communicate with the charger via the adapter. In some implementations, the controller is configured to communicate using a first communication protocol by communicating using full-duplex transmission, the charger is configured to communicate using a second communication protocol by communicating using half-duplex transmission, and the adapter is configured to convert the second communication protocol to the first communication protocol by converting the half-duplex transmission to full-duplex transmission.

[0045] In some embodiments, the second distal end includes an instrument coupler. In some embodiments, the lumen centered about the longitudinal axis of the output shaft is a first lumen, the seal includes a cylindrical shape having a second lumen, and the cannula is disposed within the second lumen. In some embodiments, the seal includes a first sealing surface on an end surface of the cylindrical shape, the end surface abutting a mating surface on the sealing plug. In some embodiments, the seal includes a second sealing surface including an annular ring-shaped surface on an inner diameter of the seal, the annular ring-shaped surface abutting an outer surface of the cannula. In some embodiments, the sealing plug includes a polymer. In some embodiments, the housing includes an internal structural insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece, the sealing plug being press-fit within the internal structural insert's inner diameter. In some embodiments, the surgical handpiece further includes a socket stopper disposed around the exterior of the internal structural insert and the sealing plug, the socket stopper configured to retain the sealing plug within the internal structural insert's inner diameter. In some embodiments, the seal is disposed in contact with the cannula flange.

[0046] In some embodiments, the battery and control module further includes a cannula access point configured to allow external access to the cannula in the first proximal end of the surgical handpiece. In some embodiments, the second distal end includes an instrument coupler. In some embodiments, the seal includes a cylindrical shape having a hollow center, and the cannula is disposed within the hollow center of the seal. In some embodiments, the seal includes a first sealing surface on an end face of the cylindrical shape that abuts a mating surface on the sealing plug, and the seal includes a second sealing surface on an inner diameter of the seal that includes an annular ring that abuts an outer surface of the cannula. In some embodiments, the battery and control module defines a pistol grip.

[0047] In some embodiments, the at least one trigger lumen includes a trigger vent cutout formed in a wall of the at least one trigger lumen, the trigger vent cutout being formed in a surface of the wall without compromising the sealing integrity of the sealed housing assembly, the trigger vent cutout being configured to allow air to escape from behind the at least one trigger when the at least one trigger is depressed or seated. In some embodiments, the at least one trigger is retained within the at least one trigger lumen by a screw and a face plate, the screw and face plate allowing the at least one trigger to be replaced without compromising the sealing integrity of the sealed housing assembly. In some embodiments, the sealed housing assembly includes two trigger lumen, and the powered surgical instrument further includes two triggers. In some embodiments, the sealed housing assembly further includes a battery including at least one battery cell. In some embodiments, the sealed housing assembly further includes a handpiece lumen configured to receive a handpiece including a modular motor configured to provide energy to the 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 housings. In some embodiments, the housings hermetically joined together are welded together by one of a vibration welding process or a laser process.

[0048] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims, and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0049] Advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when taken in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0050] [Figure 1] FIG. 1 is a perspective view of a first embodiment of a powered surgical instrument according to the teachings of the present disclosure, showing a battery and control module spaced apart from a surgical handpiece; [Figure 2] FIG. 2 is a perspective view of the control module of FIG. 1. [Figure 3] FIG. 3 is a side view of the control module of FIG. 2. [Figure 4] FIG. 3 is an exploded view of the control module of FIG. 2. [Figure 5] FIG. 5 is a perspective view of the printed circuit board assembly of FIG. 4. [Figure 6] FIG. 6 is a plan view of the printed circuit board assembly of FIG. 5. [Figure 7] FIG. 6 is a front view of the printed circuit board assembly of FIG. 5. [Figure 8] FIG. 6 is an exploded view of the printed circuit board assembly of FIG. 5. [Figure 9] FIG. 3 is a rear perspective view of the front portion of the control module of FIG. 2 in accordance with the teachings of the present disclosure. [Figure 10] FIG. 4 is a cross-sectional view of the control module of FIG. 3. [Figure 11] FIG. 5 is a perspective view of the printed circuit board and wiring assembly of the control module of FIG. 4. [Figure 12] FIG. 12 is a perspective view of the wiring assembly of FIG. [Figure 13] FIG. 13 is a rear view of the wiring assembly of FIG. 12, without the wiring shown. [Figure 14] FIG. 10 is a perspective view of a second embodiment of a powered surgical tool having a second handpiece coupled to a battery and control module. [Figure 15] FIG. 15 is a cross-sectional view of the battery and control module of FIG. 14. [Figure 16] FIG. 15 is a first perspective view of the printed circuit board assembly of the battery and control module of FIG. [Figure 17] FIG. 15 is a second perspective view of the printed circuit board assembly of the battery and control module of FIG. [Figure 18A] FIG. 17 is an exploded view of the first example printed circuit board assembly of FIG. 16. [Figure 18B] FIG. 17 is an exploded view of a second example of the printed circuit board assembly of FIG. 16. [Figure 19] 17 is a rear perspective view of a portion of the printed circuit board assembly of FIG. 16 adjacent to a portion of the battery and control module of FIG. 14. FIG. [Figure 20] FIG. 17 is a rear perspective view of the battery and control module of FIG. 14 with the printed circuit board assembly of FIG. 16 removed. [Figure 21] FIG. 3 is a cross-sectional view of a base portion of the first embodiment of the powered surgical instrument of FIG. 2 in accordance with the teachings of the present disclosure. [Figure 22] FIG. 2 is a cross-sectional view of the battery and control module of FIG. 1. [Figure 23] FIG. 10 is a perspective view of a third embodiment of a powered surgical tool having a third handpiece coupled to a battery and control module. [Figure 24] FIG. 24 is a rear perspective view of the third embodiment of the powered surgical tool shown in FIG. [Figure 25] FIG. 24 is a front perspective view of the third embodiment of the powered surgical instrument shown in FIG. 23 with the third handpiece removed. [Figure 26] FIG. 24 is a rear perspective view of the third handpiece of FIG. 23. [Figure 27] FIG. 27 is a perspective view of a portion of the interior of the third handpiece of FIG. 26. [Figure 28] FIG. 27 is a perspective view of the exterior of the third handpiece of FIG. 26. [Figure 29] FIG. 27 is a cross-sectional view of the third handpiece of FIG. 26. [Figure 30] FIG. 10 is a cross-sectional view of a fourth handpiece. [Figure 31] FIG. 31 is a perspective view of the fourth handpiece of FIG. 30. [Figure 32] FIG. 10 is a perspective view of a portion of the interior of a fifth handpiece. [Figure 33] FIG. 33 is a cross-sectional view of the fifth handpiece of FIG. 32. [Figure 34] FIG. 2 is a perspective view of a first embodiment of a pin of the battery and control module of FIG. 1. [Figure 35] FIG. 2 is a perspective view of a second embodiment of a pin of the battery and control module of FIG. 1. [Figure 36] 15 is a perspective view of a charging module and charging adapter, the charging module coupled to the battery and control module of FIG. 1 and the battery and control module of FIG. 14 via the charging adapter. [Figure 37] FIG. 37 is a perspective view of the charging module and charging adapter of FIG. 36, with the charging adapter not received in the charging module. [Figure 38] FIG. 37 is a perspective view of a module protrusion of the charging adapter of FIG. 36. [Figure 39] FIG. 37 is an exploded view of the charging adapter of FIG. 36. [Figure 40] FIG. 37 is a bottom view of the charging adapter of FIG. 36. [Figure 41] 37 is a schematic diagram of the battery and control module of FIG. 1, the battery and control module of FIG. 14, the charging adapter of FIG. 36, and the charging module of FIG. 36. [Figure 42] FIG. 1 is a perspective view of a programming jig. [Figure 43] FIG. 43 is a front view of the programming jig of FIG. 42. [Figure 44] FIG. 1 is a schematic diagram of a system for identifying devices coupled to a powered surgical tool. [Figure 45] FIG. 2 is a state diagram illustrating the operation of a system for identifying devices coupled to the powered surgical tool shown in FIG. 1. [Figure 46] 24 is a graph showing the sensed readings of the analog Hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIG. 14 or FIG. 23 when not coupled with a device. [Figure 47]24 is a graph showing the sensed readings of the analog Hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIG. 14 or FIG. 23 when coupled to a handpiece. [Figure 48] 24 is a graph showing ideal sensed readings of the analog Hall effect sensors of the battery and control module of FIG. 1 or the battery and control module of FIG. 14 or FIG. 23 when coupled to a handpiece. [Figure 49] 37 is a graph showing the detected readings of the analog Hall effect sensors of the battery and control module of FIG. 1, or the battery and control module of FIG. 14 or FIG. 23, when coupled with the charging module of FIG. 36. [Figure 50] 42 and 43. FIG. 43 is a graph showing the detected readings of the analog Hall effect sensors of the battery and control module of FIG. 1, or the battery and control module of FIG. 14 or FIG. 23, when coupled with the programming fixture of FIGS. 42 and 43. [Figure 51] FIG. 2 is a schematic diagram of an exemplary battery and control module in a front perspective view. [Figure 52] FIG. 52 is a schematic rear perspective view of the battery and control module of FIG. 51. [Figure 53] FIG. 52 is a schematic side view of an attachment or surgical handpiece configured to be attached to the battery and control module of FIG. 51 . [Figure 54] 54 is a schematic cross-sectional view of the surgical handpiece of FIG. 53 including a combined sealing plug and seal configured to seal the interior of the surgical handpiece and prevent liquid from entering the interior. [Figure 55] 1A-1C illustrate an embodiment of a powered surgical tool in which the device housing for the battery and control module is designed to provide improved ergonomics and ease of use. [Figure 56] FIG. 56 shows a side perspective view of the internal components of the battery and control module, including a pair of trigger sensors corresponding to the triggers of FIG. 55. [Figure 57] 57 is a rear perspective view of a front housing configured to be assembled, welded, laser attached, or otherwise secured to the handle portion of the intermediate housing of FIG. 56. FIG. [Figure 58] FIG. 1 illustrates a side perspective view of a sealed housing assembly including a front housing hermetically welded, laser attached, glued, fastened, or otherwise attached to a middle housing. [Figure 59] FIG. 59 is a side perspective view of the sealed housing assembly of FIG. 58 with a trigger installed. [Figure 60] FIG. 60 shows the sealed housing assembly and trigger of FIG. 59 in an exploded state. [Figure 61] FIG. 10 is a side cross-sectional view of a portion of the sealed housing assembly and a trigger. [Figure 62] FIG. 10 is a front cross-sectional view of a portion of the sealed housing assembly and the trigger. [Figure 63] FIG. 10 illustrates a front perspective view of a portion of a sealed housing assembly including multiple trigger vent cutouts. [Figure 64] FIG. 10 shows a front cross-sectional view of a portion of a sealed housing assembly including a stem portion and respective trigger vent cutouts. [Figure 65] 1 is a flowchart illustrating an example of a method for operating a powered surgical tool. [Figure 66] 1 is a flowchart illustrating an example of a method for repairing a powered surgical tool. DETAILED DESCRIPTION OF THE INVENTION

[0051] FIG. 1 illustrates an embodiment of a powered surgical tool 20 in which a device housing 22 for a battery and control module 21 is designed to provide improved ergonomics and ease of use. The powered surgical tool 20 includes a handpiece 24 configured to be removably coupled to the battery and control module 21. The handpiece 24 may include a motor and drive train (not shown), as well as additional subcomponents such as an electrical socket, a gearbox, and configuration for removably receiving a cutting accessory, including a head. Except for certain features thereof, which will be described in more detail below, the handpiece 24 may take the form disclosed in commonly owned International Publication No. WO 2013 / 177423, published November 28, 2013, the entire contents of which are incorporated herein by reference.

[0052] The cutting accessory assembly may be specific to a complementary version of the motor and drivetrain, providing a set of handpieces configured to be selectively and interchangeably coupled to the battery and control module 21. With further reference to FIG. 1 , the powered surgical instrument 20 is shown having a coupling 26 for attaching a cutting accessory, such as a sagittal saw blade. Medical professionals may use a sagittal saw blade to cut bone, e.g., oscillating bones, ligaments, or other tissue in a patient's limbs. Any device or accessory applied to a surgical site, whether a sagittal saw blade or a drill bit, may be generally referred to throughout this specification as an energy applicator. In other embodiments, the powered surgical instrument 20 may be a rotary drill, a reamer, a wire driver, an oscillating or reciprocating saw, an ultrasonic device, or a photonic device. Similarly, the energy applicator may be a drill bit, a burr, a saw, a reamer, an abrasive disk, an ultrasonic cutting tip or catheter insertion tip, a laser, or the like. The type of instrument used is not intended to limit the invention. The motor may be a universal motor capable of interchangeably accepting two or more cutting accessories, as described below. It will be further understood that a set of handpieces can be interchangeably coupled with battery and control modules 21 providing a pencil-grip configuration (FIGS. 1-13) and battery and control modules 221, 421 providing a pistol-grip configuration (FIGS. 14-23 and 23-25). The powered surgical instrument 20 of the present disclosure may be particularly well suited for orthopedic surgical procedures involving the arms, hands, legs, feet, mandible, and skull, although other small bone orthopedic and soft tissue procedures are also contemplated. FIG. 2 shows the battery and control module 21 with the handpieces removed. FIG. 3 shows a side view of the battery and control module 21.

[0053] 4 and 5, the battery and control module 21 includes at least one battery 28 and a main controller 31 coupled to a printed circuit board assembly 33, as described in more detail below. The main controller 31 is configured to communicate with the battery 28, which may be part of the battery assembly 30, the motor control sensor 32, and the handswitch sensor 34, and to communicate with the motor when the handpiece 24 is removably coupled to the battery and control module 21. The main controller 31 may also communicate with a memory device 95 (shown in FIG. 8). The battery and control module 21 may include a handswitch assembly 36, which is 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 handswitch assembly 36 may be spring-loaded and include a handswitch magnet such that the handswitch magnet moves toward the handswitch sensor 34 when the handswitch assembly 36 is actuated. Although an example is provided in which handswitch assembly 36 is coupled to battery and control module 21, handswitch assembly 36 may be detachable and attached to any portion of battery and control module 21 and / or handpiece 24. Furthermore, handswitch assembly 36 may be part of handpiece 24 or attached to handpiece 24.

[0054] The main controller 31 receives signals from the hand switch sensor 34 and causes power to be drawn from at least one battery cell 28 to be supplied to 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. Alternative embodiments may not include one or more hand switch sensors 34, and the motor may be controlled through other means. The operating speed of the powered surgical tool 20 may be increased incrementally as the hand switch assembly 36 is actuated between the default position and the fully engaged position. Additional functionality of the main controller 31, hand switch assembly 36, and other electronic subcomponents of the powered surgical tool 20 may be disclosed in the aforementioned International Publication No. WO 2013 / 177423. The main controller 31 may be configured to adjust the power drawn from the rechargeable module based on movement of the lever 66.

[0055] The main controller 31 can also receive signals from a hand switch sensor 34 .

[0056] In some cases, the handswitch sensor 34 is further defined as two handswitch sensors. Thus, the controller can be configured to receive signals from both sensors and adjust the power drawn from the rechargeable battery module based on both sensor signals. Both the first handswitch sensor and the second handswitch sensor 34 are mounted on the same side of the printed circuit board 87 or on opposite sides of the printed circuit board 87. Thus, the lever 66 can be configured to receive input from a user to cause power to be drawn from the rechargeable battery module and provided to the handpiece motor.

[0057] Referring now to FIG. 1 , a first embodiment of a powered surgical tool 20 is shown. The device housing 22 defines a recess 40 sized to removably receive the handpiece 24. More specifically, the device housing 22 includes a front surface 42 that defines an opening 44 extending proximally and defining the recess 40. The recess 40 may be at least substantially cylindrical to conform to 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 subcomponents 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 to establish communication between the motor and the main controller 31. These subcomponents may include one or more motor pins 48 (shown in FIG. 4 ) or other terminal configurations that provide a connection of the battery and control module 21 to the handpiece 24. These subcomponents may include latches and sensors, as described in more detail below. Some of these subcomponents are disclosed in the aforementioned WO 2013 / 177423, the contents of which have been previously incorporated by reference. The instrument 20 may also include a light guide 63 that directs light from one or more light sources on the printed circuit board assembly to the user.

[0058] 1, module housing 22 of battery and control module 21 receives handpiece 24, it should be noted that in other examples, handpiece 24 may be configured to receive components of battery and control module 21. For example, handpiece 24 may define a recess sized to removably receive module housing 22 of battery and control module 21.

[0059] The device housing 22 may further define a recess for positioning the latch assembly 52. ​​The latch assembly 52 may include a locking member 54 and a biasing member.

[0060] As previously mentioned, the handswitch assembly 36 can be coupled to the device housing 22. Referring to FIG. 4 , the device housing 22 can define a mounting base 56. The mounting base 56 can be integral with the device housing. Furthermore, both the device housing 22 and the integral mounting base 56 can be formed from a plastic material. The mounting base 56 can define apertures 58 adjacent to and on either side of the handswitch recess 50. The handswitch assembly 36 can be partially located within the handswitch recess 50 or channel.

[0061] The handswitch assembly 36 may be length-adjustable relative to the device housing 22. The handswitch assembly 36 may further include a push pin 60 and a receiving pin 62. Each of the pins 60, 62 extends through one of the apertures 58. The push pin 60 is pressed into a hole defined by the receiving pin 62 during assembly. When the pins are pressed together, the receiving pin defines a pivot axis 64 and a pivot surface. The push pin 60 and the receiving pin 62 thus define a press-fit engagement with each other. The handswitch assembly 36 further includes a lever 66 pivotally coupled to the pivot surface of the receiving pin 62. The lever 66 may define an aperture that receives the receiving pin, allowing the lever 66 to pivot about the receiving pin 62. Because the plastic housing defines a channel, the lever 66 is pivotable about the receiving pin 62 between a first, fully depressed position and a second, undepressed position. The lever 66 is at least partially disposed within the handswitch recess or channel 50 in both the first fully depressed position and the second undepressed position.

[0062] 3 and 4 , in some cases, the device housing 22 defines a recess 68. The recess 68 is positioned adjacent the aperture 58, and the recess 68 includes a flat surface 70. The receiver 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 receiver pin 62 is positioned within the opening 58 such that the flat pin surface 76 of the head 72 engages with the flat surface 70 of the recess 68. It is contemplated that the pressure pin may include similar features with respect to the head and shaft and flat surface, and that the other of the apertures 58 may include a similar recess with a similar flat surface. The engagement of the pin flat surface 76 and the flat surface 70 of the recess 68 contact each other to prevent the receiver pin from rotating relative to the device housing 22.

[0063] 4, the handswitch assembly 36 may further 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 to surround the pivot surface of the bearing pin 62.

[0064] The lever 66 may further include an actuation-safety switch 84 slidably mounted to the lever 66, a switch magnet attached to the actuation-safety switch, and a lever extension movably coupled to the lever 66. When the actuation-safety switch 84 is in the "actuation" position and the user presses the lever, the magnet moves up and down. The Hall sensor voltage of the hand switch sensor changes as the magnet moves toward or away from the sensor. This voltage change is used to control speed. When the actuation-safety switch is in the "safe" position, the magnet moves forward, as if the magnet were out of range. This ensures that when the user presses the lever, the hand switch sensor does not detect a significant voltage change. Therefore, the handpiece does not operate.

[0065] 5-7 , the printed circuit board assembly 33 can include a board mount 86 and a rigid printed circuit board 87. While a single printed circuit board is shown in these figures, it is contemplated that alternative configurations can separate the motor control sensor and electrical components, such as the microcontroller and MOSFET, 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 can include a set of protrusions 88 shaped to align with a plurality of cutouts 90 defined by the device housing 22. The set of protrusions 88 engage with the set of cutouts 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 degrees of freedom. Each of the protrusions 88 can further define a receptacle 92 for securing the position of the motor control sensor 32 relative to the board mount 86. The motor control sensor 32 can be inserted into the receptacle 92. The motor control sensor(s) 32 may be mounted on the surface of the printed circuit board 87 instead of being mounted in a receptacle on the board mount 86. The motor control sensor(s) may be implemented as analog Hall effect sensors.

[0066] 8, the board mount 86 may be secured to the device housing 22 using a plurality of mount fasteners 96. The mount fasteners 96 may extend through the board mount 86 and engage apertures in the device housing 22 to secure the position of the printed circuit board assembly 33 with additional degrees of freedom.

[0067] 10, a set of protrusions 88 may be positioned in an arcuate arrangement relative to one another. The set of protrusions 88 may engage a set of notches 90 on the device housing 22 such that relative movement between the printed circuit board assembly 33 and the device housing 22 is prevented in multiple degrees of freedom.

[0068] 4, the printed circuit assembly 33 is further secured in place to the device housing 22 by a plurality of mounting legs 94 located opposite the set of protrusions 88 of the rigid printed circuit board 87. The mounting legs 94 are positioned to engage with the inner surface of the device housing 22 when the printed circuit board assembly 33 is inserted into the device housing 22.

[0069] The contemplated board mount arrangement provides several advantages. For example, by coupling the board mount to a printed circuit board containing the motor control sensor, the position of the motor control sensor can be precisely controlled. Additionally, by the board mount engaging only one major surface of the circuit board, the circuit board can expand during thermal cycling without compromising the resiliency of the device. Furthermore, by the board mount engaging only the smaller surface of the circuit board, additional flexibility is provided to the larger circuit board, thereby making the larger circuit board more resistant to damage caused by torque during use of the powered surgical tool.

[0070] As described in more detail below, the motor of handpiece 24 includes a plurality of magnets. With further reference to Figures 6-8 and 10, the aforementioned set of cutouts 90 can define a series of cutout crests 97 and cutout valleys 98, whereby, when handpiece 24 is inserted into device housing 22, the innermost surfaces of the cutout crests 97 are farther from the handpiece motor magnet than the innermost surfaces of the cutout valleys 98. Thus, because protrusion 88 of board mount 86 includes motor control sensor 32 and protrusion 88 of board mount 86 is aligned with notch valleys 98, motor control sensor 32 is closer to the handpiece magnet than if it were aligned with notch crest 97.

[0071] Referring to FIG. 4 , the device housing 22 is formed to include a vent opening 100 for venting the void space. For example, the void space can be vented during sterilization. A cap 101 is coupled to the device housing 22 to cover the vent opening 100. A pressure relief valve 102 is at least partially inserted within the vent opening 100 to facilitate venting the void space during sterilization. The cap 101 can cover the pressure relief valve 102 and protect it from damage / impact, for example, by jets from a washer during cleaning. The pressure relief valve 102 can be configured to open at a predetermined pressure. When the valve is open, a gap exists between the pressure relief valve 102 and the cap 101. The cap 101 can include one or more notches adjacent or proximate to the location of the pressure relief valve 102. These notches allow gas / air to escape.

[0072] 9-13, the battery and control module 21 includes at least three motor pins 48, spaced apart to define an array of motor pins 48 that extend through the housing and out of the cavity for establishing electrical connections between the circuit board and the electric motor of the handpiece 24. It is contemplated that the battery and control module 21 may include at least six motor pins 48, with the plurality of motor pins 48 positioned equally spaced from the center of the array. The device housing 22 and the at least three motor pins 48 define a hermetically sealed housing-terminal interface. The battery and control module 21 may further include a plurality of pin wires 104, e.g., at least three wires, including wire terminals 106 connected to first wire ends of the at least three pin wires 104, the other ends of which are connected to the rigid printed circuit board 87 by a suitable connection method, such as a board wire terminal.

[0073] Each of the wire terminals 106 includes a first end 108 and a second end 110 opposite the first end, where the first end 108 is connected to one of the at least three wires 104 and the second end 110 is configured to electrically engage one of the motor pins 48. More specifically, the first end 108 of the wire terminal 106 can define a plurality of arms 118, which are crimped to engage the first wire end. The second end 110 of the wire terminal 106 can define a cylindrical cavity 120, which is sized to be disposed around the motor pin 48. The second end 110 can be soldered to the motor pin 48.

[0074] The battery and control module 21 further includes a routing mechanism 112 disposed within the housing cavity and surrounding the at least three motor pins 48, the routing mechanism 112 defining a plurality of channels 114. The routing mechanism 112 may be integral with the device housing 22 or may be a separate component secured to the device housing 22. Each of the wire terminals 106 is positioned within one of the channels 114 of the routing mechanism 112. The plurality of channels 114 may include a first channel 114 and a second channel 114'. The plurality of channels 114 secure different radial positions of the wire terminals 106 around the routing mechanism 112. The first channel 114 has a first depth, and the second channel 114' includes a second depth, where the first depth is different from the second depth. This allows the pin wires 104 and their corresponding wire terminals 106 to be offset from one another, in this case, axially. The described embodiment allows for compact axial routing of the pin wires 104, which contributes to a smaller device housing 22. Additionally, the embodiment ensures that the wires are routed in a manner that minimizes stress on the bends in the wires, ensuring maximum reliability of the battery and control module.

[0075] In some cases, the routing mechanism 112 includes a rim 116 disposed about the periphery of the routing mechanism 112 and surrounding the motor pin 48. The rim 116 may define a plurality of channels 114. When the routing mechanism 112 includes the rim 116, the first end 108 of each wire terminal 106 is disposed inside the rim 116 and the second end 110 of the wire terminal 106 is disposed outside the rim 116. The wire terminals 106 define a bend of at least 70 degrees, where the first end 108 of the wire terminal 106 is separated from the second end 110 of the wire terminal 106 by the bend.

[0076] As can be seen in FIG. 9 , at least one motor pin 48 of the at least three motor pins 48 defines a longitudinal axis, the circuit board 87 defines a longitudinal axis, and the longitudinal axis of the at least one motor pin 48 is parallel to the longitudinal axis of the circuit board 87.

[0077] Referring to FIG. 22 , a cross section of the powered surgical tool 20 is shown. As can be seen, 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 can include a plurality of motor magnets 124 surrounding a motor shaft 126 or rotor. For example, the motor 122 can include a first rotor magnet 123 and a second rotor magnet 125 forming a rotor magnet pair 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 lamination 128 or laminations that surround a portion of the motor magnet 124. A portion of the plurality of motor magnets 124 extends axially beyond the lamination 128. By having multiple magnets extend beyond the laminated member 128 in this manner, the magnetic fields of multiple motor magnets 124 can be sensed.

[0078] In other examples, motor 122 can include any suitable number of rotor magnets to form any suitable number of corresponding rotor magnet pairs. For example, if motor 122 is a three-phase motor, motor 122 can include six rotor magnets forming three rotor magnet pairs. In such cases, the rotor magnets can be positioned anywhere along motor 122, for example, evenly spaced along motor 122. If motor 122 includes three rotor magnet pairs, the rotor magnet pairs can be positioned such that the first magnet of one rotor magnet pair is positioned 120 degrees from the first magnet of each of the other rotor magnet pairs.

[0079] The motor 122 can further include a handpiece circuit 130, which optionally includes a memory device and data terminals in communication with the handpiece circuit 130 and the memory device. The data terminals are configured to connect with data pins 48' of the battery and control module 21 when the handpiece 24 is received in the recess 40. Thus, the data terminals 133 are in electrical communication with the memory device. It is contemplated that the term memory device may be interchangeable with a microcontroller that includes an on-board memory storage device. Alternatively, the handpiece circuit may include a separate processor and a dedicated memory device in communication with the processor.

[0080] As illustrated in FIGS. 5 and 6 and 22, the battery and control module 21 can include one or more motor control sensors 32, which can define a set of motor control sensors 32. For example, the motor control sensors 32 of the battery and control module 21 shown in FIGS. 5 and 6 and 22 can be one or more analog Hall effect sensors 32 coupled to the control module controller 31 and configured to sense a magnetic field. In the case of FIG. 22, the battery and control module 21 includes a first analog Hall effect sensor 32(1), a second analog Hall effect sensor 32(2), and a third analog Hall effect sensor 32(3). The one or more motor control sensors 32 can be coupled to the printed circuit board assembly 33 by mounting them on a surface of a rigid printed circuit board 87, as shown in FIG. 5.

[0081] 5, 6, and 22, the battery and control module 21 can further include one or more wake-up sensors 134, which can define a set of wake-up sensors 134. A set of wake-up sensors 134 can be defined as at least three wake-up sensors 134. The one or more wake-up sensors 134 can be positioned on the rigid printed circuit board 87 distal to the motor control sensor 32 and secured to the board mount 86 in a manner similar to that described for the motor control sensor 32. Additionally or alternatively, the one or more wake-up sensors 134 can be mounted directly 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 can be positioned to partially surround the handpiece 24 such that the three or more wake-up sensors radially surround the plurality of motor magnets 124. This arrangement of three or more wake-up sensors 134 improves accuracy because it accounts for the possibility that one or more of the wake-up sensors 134 may be aligned with gaps between multiple motor magnets. Three wake-up sensors 134 essentially guarantee that at least one of the wake-up sensors will detect a strong magnetic field regardless of the rotation of the motor 122.

[0082] As described in more detail below, the battery and control module 21 can be configured to couple with the handpiece 24, the charging module 1100 (shown in FIGS. 36 and 37), or the programming jig 1200 (shown in FIGS. 42 and 43). In such cases, one or more wake-up sensors 134 can be positioned to partially surround the handpiece 24, the charging module 1100, or the programming jig 1200 when one of the handpiece 24, the charging module 1100, or the programming jig 1200 is coupled to the battery and control module 21. This placement of the one or more wake-up sensors 134 improves accuracy by ensuring that the one or more wake-up sensors 134 sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled to the module housing 22, the magnetic field generated by the charger module magnet M (shown in FIG. 37 ) when the charging module 1100 is coupled to the module housing 22, or the magnetic field generated by the programming fixture magnet 1204 (shown in FIGS. 42 and 43 ) when the programming fixture 1200 is coupled to the module housing 22. In one such example, the wake-up sensors 134 may be positioned to surround the multiple motor magnets 124 when the handpiece 24 is coupled to the battery and control module 21.

[0083] The set of motor control sensors 32 may be aligned with one another in a direction perpendicular to the axis of the motor 122. Similarly, the set of wake-up sensors 134 may be aligned with one another in a direction perpendicular to the axis of the motor 122. The set of wake-up sensors 134 may be positioned parallel to the set of motor control sensors 32.

[0084] The control module controller 31 may include any suitable number of motor control sensors 32 for sensing the magnetic fields generated by the motor 122. As previously mentioned, the motor 122 may include any suitable number of rotor magnets to form any suitable number of corresponding rotor magnet pairs. For example, if the motor 122 is a three-phase motor, the motor 122 may include six rotor magnets forming three rotor magnet pairs. In such a case, the control module controller 31 may include three motor control sensors 32 for sensing the magnetic fields generated by each of the rotor magnet pairs.

[0085] The control module controller 31 can include any suitable number of wake-up sensors 134. For example, the control module controller 31 can include a set of three or more wake-up sensors 134. The control module controller 31 can 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 may be misaligned with the rotor magnet pairs 123, 125, the charger module magnet M, or the programming fixture magnet 1204.

[0086] As described in more detail below, the one or more wake-up sensors 134 can be configured to provide a sensor signal indicative of the presence of the hand piece 24 fully received within the battery and control module 21. With further reference to FIG. 22 , it is contemplated that when the hand piece 24 is received within 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 can be aligned with that portion of the plurality of motor magnets 124 that extends beyond the stack 128.

[0087] As described in more detail below, the main controller 31 can be configured to regulate power provided to one or more motor pins 48 of the battery and control module 21 based on a sensor signal provided by the wake-up sensor 134. More specifically, the main controller 31 can provide power to one or more motor pins 48 based on a sensor signal 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.

[0088] However, it is contemplated that the wake-up sensor 134 may be omitted, and the main controller 31 may be configured to adjust the power supplied to one or more motor pins 48 based on the sensor signal provided by the motor control sensor 32. In this case, the main controller 31 commutates the motor 122 based on the output of the motor control sensor 32, and wakes up the battery and control module 21 based on the output of the motor control sensor 32.

[0089] One or more wake-up sensors 134 may be implemented as digital Hall effect sensors, and one or more motor control sensors 32 may be implemented as analog Hall effect sensors. Here, the wake-up sensors 134 may be referred to as digital Hall effect sensors 134, and the motor control sensors 32 may be referred to as analog Hall effect sensors 32. Digital Hall effect sensors are ideal for the wake-up function because they have a lower current consumption (less than 5 μA each) than analog Hall effect sensors (greater than 5 mA each). Analog Hall effect sensors are ideal for the motor control function because they have a higher acquisition rate than digital Hall effect sensors.

[0090] By regulating power, the main controller 31 can be implemented to transition or switch between a sleep state and an active state based on a sensor signal from the wake-up sensor 134 .

[0091] In the sleep state, the main controller 31 may stop performing some functions, such as providing power to the motor 122 of the handpiece 24. In some embodiments, the controller 31 may also stop providing power to the motor control sensor 32 when in the sleep state. The main controller 31 may still draw some energy from the battery assembly 30 while in the sleep state to remain able to provide power to the wake-up sensor 134. The main controller 31 may also still provide power to one or more of the motor pins 48, specifically referred to as data pins 48′, while in the sleep state. The data pins 48′ may be energized while the main controller 31 is in the sleep state. The data pins 48′ may also be energized while in the active state. While the main controller 31 is in the sleep state, the powered surgical instrument has a current draw of less than 5 mA from the battery assembly 30.

[0092] As mentioned above, in an alternative embodiment, the main controller 31 is configured to transition the main controller 31 from a sleep state to an active state based on a sensor signal of a wake-up sensor in one embodiment.

[0093] A switching module 159 including a plurality of MOSFETs 159 may also be coupled to the printed circuit board 87. Although the present disclosure contemplates MOSFETs as the switching elements coupled to the printed circuit board 87, other suitable transistors or switching elements may be used. The switching module 159 may be used to control the direction of movement of the motor of the handpiece 24, for example, in a forward or reverse direction.

[0094] 14-21 illustrate another embodiment of a powered surgical tool 220 shown in a pistol configuration. The pistol-configured battery and control module 221 includes a barrel 200 and a handle 201. The handle 201 extends downwardly from the barrel 200. A handpiece 224 can be inserted into a recess 240 in the barrel 200. Four battery cells 228 are disposed within the handle 201 and can be surrounded by an insulating layer to form a battery assembly 230. The battery and control module 221 can have two spring-loaded triggers 202, 203 or switches. Both triggers 202, 203 extend forward from the distally directed portion of the handle 201. A physician can actuate the triggers 202, 203 to control operation of the tool unit. The triggers 202, 203 can each include a magnet that moves when a user actuates the triggers 202, 203, as described in more detail below. The battery and control module 221 may include a pressure relief valve and cap that functions substantially similarly to the pressure relief valve and cap discussed with respect to the pencil-type configuration.

[0095] Similar to the battery control module 21, the battery and control module 221 includes at least one battery 28 in a battery assembly 230 and a main controller 231 coupled to a printed circuit board assembly 233, as described in more detail below. The main controller 231 is further configured to communicate with a battery 228, a motor control sensor 232, and a trigger sensor 235, which may be part of the battery assembly 230, and to communicate with a handpiece 224 when the handpiece 224 is removably coupled to the battery and control module 221. The main controller 231 may also communicate with a memory device 295 on the board assembly, both of which may be located on a first printed circuit board 249.

[0096] The main controller 231 can receive a signal from the trigger sensor 235, and the main controller 231 can cause power to be drawn from at least one battery cell 228 and supplied to the motor of the handpiece 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 of the motor sensed by one or more motor control sensors 232. The device housing 222 of the battery and control module 221 defines a recess 240 sized to removably receive the handpiece 224. More specifically, the device housing 222 includes a front surface 242 defining an opening 244, which extends proximally to define the recess 240. The recess 240 can be at least substantially cylindrical to conform to the handpiece 224. Alternatively, the recess can have other shapes, such as those described with respect to the battery and control module 421.

[0097] 15-18, a first printed circuit board 249, a second printed circuit board 251, and a fourth printed circuit board 255 can be disposed within the barrel 200, and a third printed circuit board 253 is disposed within the handle 201. As shown, the first printed circuit board 249 is interconnected with the second printed circuit board 251 by a board header 257, the first printed circuit board 249 is connected to the third printed circuit board 251 by a flexible circuit, and the first printed circuit board 249 is connected to the fourth printed circuit board 255 by a flexible circuit.

[0098] A plurality of motor control sensors 232 may be coupled to the second printed circuit board 251. The motor control sensors 232 may be Hall effect sensors and may be similar to the motor control sensors 32 described above. A switching module 259 including a plurality of MOSFETs 270 may also be coupled to the second printed circuit board 251. While the present disclosure contemplates MOSFETs as the switching elements coupled to the second printed circuit board 251, other suitable transistors or switching elements may be used. The switching module 259 may be used to control the direction of movement of the motor of the handpiece 224, for example, in a forward or reverse direction.

[0099] 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 switching 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 the main controller 231. The battery and control module 221 may include a light guide 263 aligned with the one or more light sources 261 on the third printed circuit board. The motor pins 248 may have form factors other than pins and may be more generally referred to as motor terminals.

[0100] The trigger sensor 235 can be disposed on a third printed circuit board 253. The trigger sensor 235 can be a Hall Effect sensor and can be similar to the hand switch sensor 34 described above. The third printed circuit board 253 is disposed inside the handle 201. In particular, the third printed circuit board 253 is disposed proximate to the triggers 202, 203, thereby enabling the plurality of trigger sensors 235 to detect the state of the triggers 202, 203, for example, when the triggers 202, 203 are actuated by a user.

[0101] The first printed circuit board 249 and the second printed circuit board 251 can each be a rigid board, with the second printed circuit board 251 and the first printed circuit board 249 arranged in a stacked configuration, and multiple motor control sensors 232 connected to the second printed circuit board 251. The main controller 231 can be mounted to the second printed circuit board 251. The second printed circuit board 251 can also include multiple wake-up sensors 334, which function as described with respect to the battery and control module 221. The first printed circuit board 249 has a larger surface area than the second printed circuit board 251. Additionally, when the handpiece 224 is coupled to the battery and control module 221, the first printed circuit board 249 is located farther from the handpiece and motor than the second printed circuit board 251.

[0102] Referring to FIG. 19 , device housing 222 can include one or more mounting posts 265 to facilitate positioning of third printed circuit board 253 within device housing 222. Third printed circuit board 253 abuts mounting posts 256 such that the axial position of third printed circuit board 253 is controlled within battery and control module 221. The axial positioning of third printed circuit board 253 is important because third printed circuit board 253 includes multiple light sources that must be aligned with light guide 263. Board mount 286 indirectly ensures alignment of the third printed circuit board within the housing by securing all degrees of freedom of the first and second printed circuit boards. Fasteners that engage the third printed circuit board secure only one degree of freedom.

[0103] The device housing 222 can further include a plurality of support ribs 267, and the apparatus can further include a board mount 286. The board mount 286 can include a plurality of wings 269 for engaging the support ribs 267.

[0104] 16 and 17 , the second printed circuit board 251 includes two major surfaces 271, and the board mount 286 contacts only one of the two major surfaces 271. The second printed circuit board 251 includes at least four side surfaces 273, and the board mount 286 contacts two or fewer of the side surfaces 273. In some configurations, the second printed circuit board 251 includes at least four side surfaces 273, and the board mount 286 does not contact any of the side surfaces 273. This configuration can be advantageous in that the printed circuit board 251 can expand laterally without being restrained by the board mount during exposure to high temperatures.

[0105] Board mount 286 includes a body portion 275 and a flange 277, the flange 277 defining holes for receiving fasteners, the flange 277 extending perpendicularly from body portion 275. Flange 277 is configured to partially secure the position of fourth printed circuit board 255. Flange 277 and mounting post 265 together secure the position of fourth printed circuit board 255.

[0106] The battery and control module 221 further includes a plurality of spacers 279 disposed between the first printed circuit board 249 and the second printed circuit board 251. Each of the plurality of spacers 279 defines a hole, and the plurality of board fasteners 281 are disposed to extend through the second printed circuit board 251, at least one hole in the plurality of spacers 279, and the first printed circuit board 249. The board mount 286 can define a plurality of mounting holes, each of the plurality of mounting holes including a threaded insert 283.

[0107] Similar to the battery and control module 21, the battery and control module 221 can include a set of protrusions 288, with the device housing defining another of a set of notches 290, where one set of protrusions 288 engages with the other set of notches 290 to prevent the board mount 286 from moving relative to the device housing 222 in multiple degrees of freedom. The set of notches 290 and / or the set of protrusions 288 are positioned in an arcuate arrangement relative to one another. Each of the set of protrusions 288 defines a receiving portion 292 for securing one of the plurality of motor control sensors 232. As described above with respect to the notch 90, the notch 290 defines a series of notch peaks 297 and notch valleys 298. The innermost surfaces of the notch peaks 297 are farther from the motor magnets than the innermost surfaces of the notch valleys 298.

[0108] The first printed circuit board 249 may be longer and wider than the second printed circuit board 251 and thus have a larger surface area than the second printed circuit board 251. For example, the surface area of ​​the first printed circuit board 249 may be at least 30, 40, or 50% larger than 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 is helpful in minimizing the footprint of the powered surgical tool 220, particularly the small footprint of the battery and control module. The first printed circuit board 249 can have a first longitudinal axis, and the second printed circuit board 251 can have a second longitudinal axis, the first longitudinal axis and the second longitudinal axis being aligned with one another. The first printed circuit board 249 and the second printed circuit board 251 can each have a rigid back layer and thus are rigid printed circuit boards.

[0109] First printed circuit board 249 is longer than second printed circuit board 251 such that the distal end of first printed circuit board 249 extends beyond the distal end of second printed circuit board 251. Additionally, second printed circuit board 251 can be positioned such that it does not extend beyond first printed circuit board 249 in any direction, except that it is spaced apart from the first circuit board as described above.

[0110] 23-25 ​​illustrate another embodiment of a powered surgical tool 420 shown in an open-top pistol configuration. A battery and control module 421 in a pistol configuration includes a receiving surface 404 and a handle 401. The handle 401 extends downwardly from the receiving surface 404. A handpiece 424 can be inserted into the receiving surface 404. The battery and control module 421 can include any of the features described with respect to the battery and control modules 21 and 221. However, the battery and control module 421 provides an open-top configuration for the handpiece 424, which provides several ergonomic and structural advantages.

[0111] 25 and 26, the handpiece 424 can include a rail 405, 404 of the battery and control module 421 defining a slot 406. The rail 405 and slot 406 are configured such that the rail is slidable within the slot 406, allowing for coupling between the handpiece 424 and the battery and control module 421. The reverse arrangement, in which the slot is defined by the handpiece and the rail is 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 can further include a latch assembly with a locking member of a structure similar to that described above with respect to the battery and control module 21. The handpiece 424 can include a receiving surface 404 similar to that of the handpiece 24.

[0112] As described above with respect to the battery and control module 21, the battery and control module 421 can include a device housing 422 defining a void space for receiving a rechargeable battery module disposed therein. The battery and control module 21 can further include a printed circuit board including a controller configured to regulate power drawn from the rechargeable battery module based on user input. The printed circuit board can further include a motor sensor configured to output a motor sensor signal representative of the status of the motor of the handpiece 424.

[0113] The battery and control module 421 may further include motor pins 448 extending through the device housing to establish an electrical connection between the printed circuit board and the motor of the handpiece 424. As mentioned above, the motor pins 448 may take 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 the battery and control module 221. The battery and control module 421 may also include one or more motor control sensors, which may be implemented as Hall effect sensors, as described above with respect to the battery and control module 221.

[0114] As described in more detail below, the handpiece 424 can take the form of a pin or wire driver defining a cannula 408. The cannula 408 allows fixation pins and wires to pass through the proximal end of the handpiece 424, extend through the handpiece body, and exit through the distal end of the handpiece. The handpiece 424 can include features of U.S. Patent Application Publication No. 20210220035, which is incorporated herein by reference in its entirety. The battery and control module 421 can eliminate a cannula and allow wires or pins to enter the proximal end of the handpiece 424. The proximal end of the battery and control module 421 can be shaped to allow wires or pins to enter the handpiece 424 from the proximal end of the instrument 420. For example, the control module 421 can define a groove 410 for accommodating the wire or pin as it enters the proximal end of the handpiece 424. Because the battery and control module is cannulated, the battery and control module 421 does not require additional welds to define such cannulae in the device housing 422. Avoiding these additional welds simplifies the design of the battery and control module 421 and eliminates potential points of entry for sterilant during the sterilization process.

[0115] 24 , the powered surgical tool 420 can be configured such that when the handpiece 424 is coupled to the battery and control module 421, the distal end face 411 of the handpiece is exposed. Additionally, when the handpiece 424 is coupled to the battery and control module 421, a portion of the proximal end face 412 of the handpiece 424 is exposed. Because the distal and / or proximal end faces of the handpiece 424 are exposed, the battery and control module 421 can be relatively small because it does not have plastic circumferentially surrounding the handpiece 424. Furthermore, by using a slot and rail arrangement to couple the handpiece 424 to the battery and control module 421, the battery and control module 421 does not have a cylindrical profile, which would otherwise make the device relatively large. This also allows the motor diameter to be increased without being too large for the user. The increased diameter allows the motor length to be reduced, thereby reducing the size of the tool.

[0116] 26-29, the handpiece 424 includes a motor 522 with a motor magnet 524 and a motor shaft 526. The motor 522 can include a laminated element 228 surrounding the motor shaft 526. The handpiece 424 can further include a handpiece circuit 530, which can be, for example, a rigid circuit board including a handpiece memory 532 and conductive terminals (one of which is a data terminal 533) that receive motor pins. The motor shaft 526 can define a cannula 536. The handpiece 424 can further include a gearbox 538 for changing an output parameter of the motor shaft output to the instrument coupler, such as the speed, torque, or direction of the output to the instrument coupler. The surgical handpiece 424 can define an axis, and the cannula 536 can surround the axis.

[0117] Referring to FIG. 29 , the motor shaft 526 or rotor can define an axis. The rigid circuit board 530 can be defined as a rigid circuit board including a controller. The rigid circuit board 530 can be oriented perpendicular to the axis of the rotor. The rigid circuit board 530 can also be cannulated via a cannulated aperture 540. The cannulated aperture 540 can be coaxial with the cannula 536. A number of terminals, including a data terminal 533, can be soldered to the rigid circuit board and shaped to engage the motor pins 448 when the handpiece 424 is coupled with the battery and control module 421. This arrangement of the rigid circuit board 530 allows the handpiece 424 to be relatively short, which in turn allows the instrument 420 to be relatively shorter and more compact than designs in which the circuit board is oriented parallel to the axis of the motor shaft.

[0118] 30 and 31, an alternative handpiece 624 is described. The handpiece 624 includes a motor 722 with a motor magnet 724 and a motor shaft 726. The motor 722 may include a laminated element 728 surrounding the motor shaft 726. The handpiece 624 may further include handpiece circuitry 730, which includes a handpiece memory 732 and conductive terminals that receive motor pins, one of which is a data terminal 733. The other motor pin may function as a power terminal and may operate at a higher voltage than the data terminal. The handpiece 624 may further include a gearbox 738 for changing output parameters of the motor shaft output to the instrument coupler, such as the speed, torque, or direction of the output to the instrument coupler.

[0119] The handpiece circuitry 730 can be defined as a rigid circuit board including a controller. The controller can be integrated with a memory device 732, not shown separately. The handpiece circuitry 730 can be oriented perpendicular to the axis of the motor shaft 726. A number of terminals, including a data terminal 733, can be soldered to the rigid circuit board and shaped to engage with the motor pins 248 when the handpiece 624 is coupled to the battery and control module 221. This arrangement of the handpiece circuitry 730 allows the handpiece 624 to be relatively short, thereby allowing the instrument 220 to be relatively short and compact. The handpiece can also be coupled to other control modules, such as the control module 21 or the control module 421.

[0120] 32 and 33, an alternative handpiece 824 will be described. The handpiece 824 includes a motor 822 with a motor magnet 924 and a motor shaft 926. The motor 922 may include a laminated element 928 surrounding the motor shaft 926. The handpiece 824 may further include handpiece circuitry 930, which includes a handpiece memory 932 and conductive terminals (one of which is a data terminal 933) that receive motor pins. The handpiece 824 may further include a gearbox 938 for changing an output parameter of the motor shaft output to the instrument coupler 826, for example, the speed, torque, or direction of the output to the instrument coupler 826.

[0121] The handpiece circuitry 930 is defined as a flexible-rigid board including a flexible portion 942 and a rigid portion 944. The rigid portion 944 can be oriented parallel to the axis of the motor shaft 926. A plurality of terminals, including a data terminal 933, can be soldered to the flexible portion 942 and configured to engage the motor pins 248 when the handpiece 824 is coupled with the battery and control module 221. This particular arrangement of rigid and flexible portions advantageously allows for a compact design while also providing space for electrical components within the handpiece, including, but not limited to, the handpiece's controller and memory device. The controller and memory device may be integrated into a single unit. In either case, these electrical components can be mounted on the rigid portion of the circuit board. It is also contemplated that this handpiece, like all handpieces described in this disclosure, can be configured to operate with the battery and control module 421.

[0122] Pins 48 of the battery and control module 21 can establish an electrical connection between the control module controller 31 and a device coupled to the battery and control module 21. Two examples of example pins 48 are shown in Figures 34 and 35.

[0123] FIG. 34 illustrates a first example of a pin 48 for establishing an electrical connection between the control module controller 31 and a device coupled to the battery and control module 21. As illustrated, the 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 electrically connect with the control module controller 31, and either the first end 1050 or the second end 1052 can be configured to electrically connect with an electrical component of a device coupled to the battery and control module 21, such as the handpiece 24. Furthermore, because the pin 48 in FIG. 34 is geometrically symmetrical, 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 inserted into the injection mold. Furthermore, the pin 48 includes an abutment 1054 defining a groove 1056. The abutment 1054 interacts with the module housing 22 to provide a seal configured to prevent vapors and liquids from entering the battery and control module 21. During the process of injection molding the pin 48 into the module housing 22, plastic flows into the groove 1056 to secure the pin 1048 to the module housing 22. The abutment 1054 is also configured to help securely secure the pin 48 to the battery and control module 21 after the pin 48 is injection molded into the battery and control module 21.

[0124] FIG. 35 illustrates a second example of a pin 48 for establishing an electrical connection between the control module controller 31 and a device coupled to the battery and control module 21. As illustrated, the pin 48 includes a first end 1058 and a second end 1060. The first end 1058 can be configured to electrically connect with the control module controller 31, and the second end 1060 can be configured to electrically connect with an electrical component of a device coupled to the battery and control module 21, such as the handpiece 24. Additionally, the pin 48 includes a half groove 1062 defined by an abutment portion 1064. The half groove 1062 is configured to receive an O-ring such that the O-ring is adjacent to the abutment portion 1064. The O-ring is configured to be sandwiched between the abutment portion 64 and the module housing 22 of the battery and control module 21 to provide a seal configured to prevent vapors and liquids from entering the interior of the battery and control module 21. Additionally, the pin 48 includes a barb 1065 that is configured to help secure the pin 48 to the battery and control module 21 while providing a seal configured to prevent vapors and liquids from entering the battery and control module 21.

[0125] Various aspects of powered surgical instruments, including various aspects of surgical handpieces and various aspects of battery and control modules, are described in PCT / IB2022 / 057637, which is incorporated herein by reference in its entirety, and therefore, any of the described features of the battery and control module or surgical handpiece described therein is expressly contemplated in combination with one or more features described in the present application.

[0126] The module housing 22 of the battery and control module 21 can be configured to be received in a charging module 1100. In the example of Fig. 36, the charging module 1100 includes a charging adapter 1102, and the module housing 22 of the battery and control module 21 is coupled to the charging module 1100 via the charging adapter 1102. As shown in Fig. 36, the recess 40 of the module housing 22 receives the charging adapter 1102, and the rechargeable battery module 28 receives charging power from the charging module 1100, as indicated by the dotted arrow.

[0127] FIG. 37 further illustrates the charging module 1100. As shown in FIG. 37, the charging module 1100 may include a recess 1104. The charging module 1100 may be configured to provide charging power to a device received in the recess 1104. For example, the recess 1104 may receive a rechargeable battery, and the rechargeable battery may be configured to receive charging power from the charging module 1100 in response to the rechargeable battery contacting the charging module 1100. The charging module 1100 may include any suitable number of recesses 1104 arranged in any suitable manner. For example, in FIG. 37, the charging module 1100 includes six recesses 1104. The six recesses 1104 are arranged in a two-row by three-column configuration, with each row including three recesses 1104 arranged along a first charger axis AX1 and each column including two recesses 1104 arranged along a second charger axis AX2 perpendicular to the first charger axis AX1.

[0128] The charging adapter 1102 is configured to modify 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 coupled to a device that is not shaped to be received by the recess 1104, thereby allowing the charging module 1100 to provide charging power to such a device. For example, referring to FIG. 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 coupled to the module housing 22, allowing the charging module 1100 to provide charging power to the rechargeable battery module 28 of the powered surgical tool 20 via the charging adapter 1102. Specifically, as shown in FIG. 37 , the charging adapter 1102 includes a charger protrusion 1108 configured to be received in the recess 1104 of the charging module 1100 and a module protrusion 1110 configured to be received in the module housing 22 of the battery and control module 21. The module protrusion 1110 is received in the module housing 22 and allows the charging module 1100 to provide power to the rechargeable battery module 28 via the charging adapter 1102 .

[0129] Furthermore, the charging adapter 1102 changes the form factor of the charging module 1100 so that a device coupled to the charging adapter 1102 extends along the direction of the module protrusion 1110. For example, as shown in FIG. 37 , the recess 1104 includes a surface 1106 facing a surface direction D1. When the charging adapter 1102 is not received in the charging module 1100, a device received in the recess 1104 of the charging module 1100 extends along the surface direction D1. As shown in FIG. 37 , the module protrusion 1110 extends along a protrusion direction D2, which is different from the surface direction D1. When the charging adapter 1102 is received in the charging module 1100, a device coupled to the charging adapter 1102 via the module protrusion 1110 extends along the protrusion direction D2. In this way, when multiple devices are coupled to the charging adapter 1102 via the module protrusion 1110, the multiple devices can be aligned for easy user access.

[0130] The charging adapter 1102 can be configured to couple with any of the embodiments of the powered surgical tool described herein. For example, the charging adapter 1102 of FIG. 36 couples with the pencil-grip powered surgical tool 20 as well as the pistol-grip powered surgical tool 220. Specifically, the charging adapter 1102 is configured to couple with 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 housing 22, 222 of the corresponding battery and control module 21, 221 couples with the charging module 1100 via the charging adapter 1102, and the corresponding rechargeable battery module 28, 228 receives charging power from the charging module 1100. In other examples, the charging module 1100 may be configured to couple with any of the other embodiments of the powered surgical tool, such as the powered surgical tool 420.

[0131] The charging adapter 1102 can include components that enable the charging adapter 1102 to couple with various embodiments of a powered surgical tool. With reference to FIG. 38 , the module protrusion 1110 includes a first portion 1112 shaped to be received in the module housing 22 of the powered surgical tool 20 and a second portion 1114 shaped to be received in the module housing 222 of the powered surgical tool 220. With reference to FIG. 36 , the first portion 1112 is shown to receive the module housing 22 of the powered surgical tool 20, and the second portion 1114 is shown to receive the module housing 222 of the powered surgical tool 220. The recess 40 of the module housing 22 (shown in FIG. 1 ) can have a first radius, and the recess 240 of the module housing 222 (shown in FIG. 15 ) can have a second radius that is different from the first radius. The first portion 1112 can have a cylindrical shape sized to be received in the recess 40 of the module housing 22, and the second portion 1114 can have a cylindrical shape shaped to be received in the recess 240 of the module housing 222.

[0132] The charging adapter 1102 may also include components to ensure proper reception of the module protrusion 1110 with various embodiments of the powered surgical tool.

[0133] 38 , the charging adapter 1102 may include an alignment feature 1116 configured to ensure that the module protrusion 1110 is properly received in the module housing 22, and an alignment feature 1116′ configured to ensure that the protrusion 1104 is properly received in the module housing 222. While the module housing 22, 222 receives the module protrusion 1110, the corresponding alignment feature 1116, 1116′ is configured to engage with the module housing 22, 222 before the pins 48, 248 of the battery and control module 21, 221 are electrically connected to the charging adapter 1102. In this manner, the alignment features 1116, 1116′ protect the pins 48 of the battery and control module 21 by ensuring that the pins 48 are received in the pin receivers 1112 of the charging adapter 1102. Additionally, the alignment features 1116, 1116′ can be configured to ensure that the module housing 22, 222 is prevented from rotating after receiving the module protrusion 1110. Alternatively, the charging adapter 1102 may include an additional feature configured to prevent the module housing 22, 222 from rotating after receiving the module protrusion 1110.

[0134] The charging adapter 1102 may also include a latch L1 configured to engage with an interface of 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 with an interface of 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.

[0135] The charging adapter 1102 can be configured to generate a magnetic field. For example, in the example of FIG. 38 , the charging adapter 1102 includes a magnet M disposed on the module protrusion 1110 configured to generate a magnetic field. In the example of FIG. 38 , the magnet M is located near the latch L1. However, in other examples, the magnet M may be disposed in any other suitable location on the charging adapter 1102 or the charging module 1100. As shown in FIG. 41 , the wake-up sensor 134 of the battery and control module 21 can be configured to detect 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 detect a magnetic field generated by the magnet M in response to the module housing 222 receiving the module protrusion 1110. The controller 31, 231 can be configured to transition from a sleep state to an active state based on the wake-up sensor 134, 334 detecting a magnetic field generated by the magnet M, wherein the controller 31, 231 is configured to communicate with a charger when the controller is in the active state.

[0136] 39, each charger protrusion 1108 of the charging adapter 1102 can include adapter contacts 1119. As shown in FIG. 40, the adapter contacts 1119 include an adapter ground contact 1120, an adapter communication contact 1122, and an adapter power contact 1124. As shown in FIG. 41, each recess 1104 of the charging module 1100 can include a charger ground terminal 1126, a charger communication terminal 1128, and a charger power terminal 1130. When the charger protrusion 1108 is received in 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.

[0137] 40 , 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 in the module housing 22, 222 of the battery and control module 21, the adapter terminal 1121 contacts the pins 48, 48′, allowing the charging adapter 1102 to facilitate communication between the charging module 1100 and the battery and control module 21, 221 and to provide charging power to the rechargeable battery of the battery and control module 21, 221.

[0138] 37, the module housing 22, 222 of the battery and control module 21, 221 is shown to receive the module protrusion 1100 of the charging adapter 1102, it should be noted that in other examples, the charging adapter 1102 may instead be configured to receive components of the battery and control module 21, 221. For example, the charging adapter 1102 may define a recess sized to removably receive the module housing 22, 222 of the battery and control module 21, 221.

[0139] The charging adapter 1102 and its components can have any appropriate structure and any suitable dimensions. Referring to FIG. 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 in the charging module 1100, the charging adapter 1102 is received in two recesses 1104 of the charging module 1100 and occupies a single row of the recesses 1104. Furthermore, the charging adapter 1102 can include two module protrusions 1110 arranged along the direction of the second charger axis AX2. Each module protrusion 1110 has a width w along the second charger axis AX2. a and may have a width w a The sum of these is the width w of the recess 1104 along the second charger axis AX2. c In this manner, the charging adapter 1102 is received in two recesses 1104 of the charging module 1100, and while occupying a single row of recesses 1104, the charging module 1100 is able to provide charging power to two powered surgical instruments coupled with the module protrusions 1110 of the charging adapter 1102. Thus, the charging adapter 1102 maintains the ability of the charging module 1100 to provide charging power to a number of devices corresponding to the number of recesses 1104.

[0140] The charging adapter 1102 can include any suitable number of charger protrusions 1108 and module protrusions 1110. For example, in FIG. 37 , the charging adapter 1102 includes a first charger protrusion 1108(1) and a second charger protrusion 1108(2) and 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 in the first recess 1104(1) and the second recess 1104(2) of the charging module 1100, as shown by the arrows in FIG. 37 . Each of the first module protrusion 1110(1) and the second module protrusion 1110(2) can be received in the module housing 22 of the battery and control module 21. For example, in FIG. 36, the module projection 1110 is shown received in the module housing 22,222 of the battery and control module 21,221.

[0141] The charging module 1100 can receive any suitable number of charging adapters 1102. For example, the charging module 1100 of FIGS. 36 and 37 includes six recesses 1104 arranged in a 2×3 grid, with each charging adapter 1102 including two charger protrusions 1108 configured to be received in two recesses 1104 along the direction of the first charger axis AX1. As follows, the charging module 1100 of FIGS. 36 and 37 is configured to receive three charging modules 1102(1), 1102(2), and 1102(3). In other examples, the charging module 1100 may include a different arrangement or number of recesses 1104.

[0142] The module housing 22 of the battery and control module 21 can be configured to couple with a programming fixture 1200 shown in Figures 42 and 43. For example, the recess 40 of the module housing 22 can receive the programming fixture 1200. Once the module housing 22 of the battery and control module 21 is received in the programming fixture 1200, a computing system coupled to the programming fixture 1200 can perform updates, repairs, or diagnostics on the control module controller 31 of the battery and control module 21.

[0143] The programming jig 1200 can be configured to couple with any embodiment of the battery and control module 21. For example, the module housing 222 of the battery and control module 221 can also be configured to couple with the programming jig 1200.

[0144] 42 and 43, the module housing 22 of the battery and control module 21 is configured to receive the programming jig 1200, but in other examples, the programming jig 1200 may be configured to receive components of the battery and control module 21. For example, the programming jig 1200 may define a recess sized to removably receive the module housing 22 of the battery and control module 21.

[0145] 42 and 43 illustrate various features of the programming jig 1200. In the example of FIGS. 42 and 43, the programming jig 1200 includes an alignment feature 1202 configured to ensure that the programming jig 1200 is properly received in the battery and control module 21, and an alignment feature 1202' configured to ensure that the programming jig 1200 is properly received in the battery and control module 221. Additionally, the alignment features 1202, 1202' can be configured to ensure that the battery and control module 21, 221 is prevented from rotating after receiving the programming jig 1200. The alignment features 1202, 1202' are configured to engage with the module housing 22, 222 when the module housing 22, 222 receives the programming jig 1200, before the pins 48 of the battery and control module 21 electrically connect with the programming jig 1200. In this manner, the alignment features 1202 , 1202 ′ protect the pins 48 of the battery and control module 21 by ensuring that they are received by the pin receivers 1206 of the programming fixture 1200 .

[0146] The programming jig 1200 can be configured to generate a magnetic field. For example, in the examples of Figures 42 and 43, the programming jig 1200 includes a magnet 1204 configured to generate a magnetic field. The magnet 1204 can be positioned at any suitable location on the programming jig 1200.

[0147] FIG. 44 illustrates a system 10 for identifying devices coupled to a powered surgical tool 20. As illustrated, the powered surgical tool 20 includes a battery and control module 21. Further, the battery and control module 21 includes a module housing 22 that is configured to couple with a handpiece 24 (shown in FIG. 2), a charging module 1100 (shown in FIG. 36), and a programming tool 1200 (shown in FIGS. 42 and 43). As shown in FIG. 44, the handpiece 100 includes a motor 122 that includes a first rotor magnet 123 and a second rotor magnet 125 that form a rotor magnet pair 123, 125, the charging module 1100 includes a magnet M, and the programming tool 1200 includes a magnet 1204. The battery and control module 21 includes a control module controller 31 configured to determine whether the module housing 22 is coupled to the handpiece 24, the charging module 1100, or the programming fixture 1200 based on sensing the magnetic fields generated by the rotor magnet pairs 123, 125, the charger module magnet M, or the programming fixture magnet 1204.

[0148] 44 illustrates system 10 as including battery and control module 21, it should be noted that system 10 can include any of the embodiments of the battery and control module described herein. For example, system 10 can include the pencil-grip configuration of battery and control module 21 of FIGS. 1-13 and the pistol-grip configurations of battery and control modules 221, 421 of FIGS. 14-23 and 23-35. The pencil-grip configurations of battery and control module 21 of FIGS. 1-13 and the pistol-grip configurations of battery and control modules 221, 421 of FIGS. 14-23 and 23-35 can be coupled to handpiece 24, charging module 1100, or programming tool 1200, as follows:

[0149] The control module controller 31 can sense magnetic fields generated in proximity to the battery and control module 21. The analog Hall effect sensor 32 shown in FIGS. 5 and 6 and 22 can be configured to sense the magnetic field generated by the rotor magnet pair 123, 125 of the motor 122. The analog Hall effect sensor 32 can also be configured to sense the magnetic field generated by the magnet M of the charging adapter 1102 (shown in FIG. 37) and the magnet 1204 of the programming fixture 1200 (shown in FIGS. 42 and 43). The analog Hall effect sensor 32 can sense the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled to the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled to the module housing 22, or the magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is coupled to the module housing 22.

[0150] The control module controller 31 may also include one or more digital Hall effect sensors 134, shown in FIGS. 5 and 6 and 22, coupled to the control module controller 31 and configured to sense a magnetic field. The digital Hall effect sensors 134 may be coupled to the printed circuit board assembly 33 by mounting them on the surface of the rigid printed circuit board 87, as shown in FIG. 5. The digital Hall effect sensors 134 may be configured to sense a magnetic field generated by the rotor magnet pair 123, 125 of the motor 122. The digital Hall effect sensors 134 may also be configured to sense a magnetic field generated by the magnet M of the charging adapter 1102 (shown in FIG. 37) and the magnetic field generated by the magnet 1204 of the programming fixture 1200 (shown in FIGS. 42 and 43).

[0151] The digital Hall effect sensor 134 can detect the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled to the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled to the module housing 22, or the magnetic field generated by the programming fixture magnet 1204 when the programming fixture 1200 is coupled to the module housing 22.

[0152] As previously described, the control module controller 31 is configured to determine whether the module housing 22 is coupled to the handpiece 24, the charging module 1100, or the programming tool 1200 based on the digital Hall effect sensor 134 detecting the magnetic field generated by the rotor magnet pairs 123, 125, the charger module magnet M, or the programming tool magnet 1204. However, before determining whether the module housing 22 is coupled to the handpiece 24, the charging module 1100, or the programming tool 1200, the control module controller 31 is configured to operate in a sleep state and transition from the sleep state to an active state.

[0153] It should be noted that the main controller 231 of the battery and control module 221 may similarly be configured to determine whether the module housing 222 is coupled to the handpiece 24, the charging module 1100, or the programming fixture 1200 based on the digital Hall effect sensor 334 sensing the magnetic field generated by the rotor magnet pairs 123, 125, the charger module magnet M, or the programming fixture magnet 1204. The discussion herein regarding the main controller 31 should be construed as applying to the main controller 231 as well.

[0154] 45, in the sleep state, the digital Hall effect sensor 134 is active and the analog Hall effect sensor 32 is inactive. In other words, during the sleep state, the digital Hall effect sensor 134 is configured to sense magnetic fields, such as those generated by the rotor magnet pair 123, 125, the charger module magnet M, or the programming fixture magnet 1204, while the analog Hall effect sensor 32 is unable to sense magnetic fields. In the sleep state, 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.

[0155] 45, when the digital Hall effect sensor 134 detects a magnetic field, the control module controller 31 transitions to the active state. For example, the digital Hall effect sensor 134 can detect the magnetic field generated by the rotor magnet pair 123, 125 when the handpiece 24 is coupled to the module housing 22, the magnetic field generated by the charger module magnet M when the charging module 1100 is coupled to the module housing 22, or the magnetic field generated by the programming tool magnet 1204 when the programming tool 1200 is coupled to the module housing 22. Thus, when one of the handpiece 24, the charging module 1100, or the programming tool 1200 is coupled to the module housing 22, the control module controller 31 transitions to the active state.

[0156] In the active state, the analog Hall effect sensor 32 is configured to sense a magnetic field and receive power from the rechargeable battery module 28. In some cases, the digital Hall effect sensor 134 is inactive during the active state and does not receive power from the rechargeable battery module 28. In an alternative example, the digital Hall effect sensor 134 is also active during the active state and receives power from the rechargeable battery module 28.

[0157] In this manner, the digital Hall effect sensor 134 functions as a wake-up sensor. In some cases, the analog Hall effect sensor 32 receives more power from the rechargeable battery module 28 during the active state than the digital Hall effect sensor 134 receives during the sleep state. Advantageously, the analog Hall effect sensor 32 is inactive and does not receive power during the sleep state, thereby conserving power provided to the sensors 134, 32. Furthermore, by detecting the presence of a magnetic field with the digital Hall effect sensor 134, as opposed to the analog Hall effect sensor 32, the control module controller 31 can detect whether the handpiece 24, charging module 1100, or programming tool 1200 is coupled to the battery and control module 21 while minimizing the power provided 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 current consumption of analog Hall effect sensors (more than 5 mA each). Additionally, analog Hall effect sensors have higher acquisition rates than digital Hall effect sensors, making them ideal for motor control functions.

[0158] During the active state, one of the handpiece 24, the charging module 1100, or the programming tool 1200 is coupled to the module housing 22. The control module controller 31 can then be configured to determine whether the module housing 22 is coupled to the handpiece 24, the charging module 1100, or the programming tool 1200 based on sensing the magnetic fields generated by the rotor magnet pairs 123, 125, the charger module magnet M, or the programming tool magnet 1204. Control module controller 31 can determine whether module housing 22 is coupled to handpiece 24, charging module 1100, or programming tool 1200 based on the sensed readings SR1, SR2, SR3 provided by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3), where the sensed readings SR1, SR2, SR3 correspond to the magnitude of the magnetic field sensed by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3).

[0159] 46 shows example sensed readings SR1, SR2, SR3 provided by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) while control module controller 31 is in a sleep state. As shown, first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) simply provide offset voltages for body and control module 21 because none of handpiece 24, charging module 1100, or programming tool 1200 are coupled to module housing 22, and first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) do not sense magnetic fields generated by handpiece 24, charging module 1100, or programming tool 1200.

[0160] FIG. 47 shows example sensed readings SR1, SR2, SR3 provided by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) while control module controller 31 is in an active state and while handpiece 24 is coupled to module housing 22. In the example of FIG. 47, handpiece 24 includes three rotor magnet pairs that rotate motor 122. FIG. 48 shows an idealized representation of example sensed readings SR1, SR2, SR3. As shown, sensed readings SR1, SR2, SR3 are sinusoidal and have a 120-degree phase difference corresponding to the position of the rotor magnet pairs on motor 122. Thus, the magnitude of the magnetic field sensed by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) varies sinusoidally when handpiece 24 is coupled to module housing 22.

[0161] FIG. 49 shows example sensed readings SR1, SR2, SR3 provided by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) while control module controller 31 is in an active state and while charging module 1100 is coupled to module housing 22. In the example of FIG. 49, first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) sense magnet M of charging module 1100. However, because charging module 1100 does not rotate while coupled to module housing 22, the magnitudes of the magnetic fields sensed by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) remain relatively constant when charging module 1100 is coupled to module housing 22.

[0162] 50 shows example sensed readings SR1, SR2, SR3 provided by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) while control module controller 31 is in an active state and while programming fixture 1200 is coupled to module housing 22. In the example of FIG. 50, first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) sense magnet 1204 of programming fixture 1200. However, because programming fixture 1200 does not rotate while coupled to module housing 22, the magnitude of the magnetic field sensed by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) remains relatively constant when programming fixture 1200 is coupled to module housing 22.

[0163] Control module controller 31 can determine whether module housing 22 is coupled to handpiece 24, charging module 1100, or programming tool 1200 based on the detected readings SR1, SR2, and SR3 provided by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3). For example, if the magnitude of the magnetic field detected by first analog Hall effect sensor 32(1), second analog Hall effect sensor 32(2), and third analog Hall effect sensor 32(3) varies sinusoidally, control module controller 31 can determine that handpiece 24 is coupled to module housing 22. If the magnitude of the magnetic field sensed by the first analog Hall effect sensor 32(1), the second analog Hall effect sensor 32(2), and the third analog Hall effect sensor 32(3) is relatively constant, the control module controller 31 can determine that either the charging module 1100 or the programming jig 1200 is coupled to the module housing 22.

[0164] Because the magnitudes of the magnetic fields sensed by the first analog Hall effect sensor 32(1), the second analog Hall effect sensor 32(2), and the third analog Hall effect sensor 32(3) are relatively constant when the charging module 1100 is coupled to the module housing 22, the control module controller 31 can use various methods to determine whether the charging module 1100 or the programming tool 1200 is coupled to the module housing 22. For example, the control module controller 31 can determine that the charging module 1100 or the programming tool 1200 is coupled to the module housing 22 by comparing the sensed readings SR1, SR2, and SR3 to constant values. As in FIG. 49 , if the first sensed reading SR1 is greater than the third sensed reading SR3, the control module controller 31 can determine that the charging module 1100 is coupled to the module housing 22. If the first detected reading SR1 is less than the third detected reading SR3, as in FIG. 50, the control module controller 31 can determine that the programming tool 1200 is coupled to the module housing 22.

[0165] The positions of the magnets 310, 404 can be selected to enable the control module controller 31 to determine whether the charging module 1100 or the programming fixture 1200 is coupled to the module housing 22. For example, the position of the magnet 1204 of the programming fixture 1200 and the position of the magnet M of the charging module 1100 can be selected so that the magnitude of the magnetic field generated by the magnet 1204 and sensed by the analog Hall effect sensor 32 is different from the magnitude of the magnetic field generated by the magnet M and sensed by the analog Hall effect sensor 32. For example, the magnet 1204 can be positioned at a position around the periphery of the programming fixture 1200 and the magnet M can be positioned at a position around the protrusion 1104 so that the magnet 1204 is aligned with the first analog Hall effect sensor 32(1) when the programming fixture 1200 is coupled to the module housing 22 and the magnet M is aligned with the third analog Hall effect sensor 32(3) when the charging module 1100 is coupled to the module housing 22.

[0166] The polarity of magnets M, 1204 can be selected to enable control module controller 31 to determine whether charging module 1100 or programming fixture 1200 is coupled to module housing 22. For example, the polarity of magnet 1204 of programming fixture 1200 and the polarity of magnet M of charging module 1100 can be selected so 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, 310 can be polarized so that when programming fixture 1200 is coupled to module housing 22, first analog Hall effect sensor 32(1) senses a magnetic field of positive polarity, and when charging module 1100 is coupled to module housing 22, first analog Hall effect sensor 32(1) senses a magnetic field of negative polarity.

[0167] The control module controller 31 can determine whether the module housing 22 is coupled to the handpiece 24, the charging module 1100, or the programming tool 1200 in order to properly communicate with the handpiece 24, the charging module 1100, or the programming tool 1200. For example, one or more of the handpiece 24, the charging module 1100, and the programming tool 1200 can be configured to communicate with the control module controller 31 using different communication protocols, and communication can be initiated using different methods.

[0168] In one example, the control module controller 31 can be configured to communicate with the handpiece 24, the charging module 1100, or the programming fixture 1200 using different communication protocols. In one such example, the control module controller 31 can be configured to communicate with the handpiece 24 using a first communication protocol in response to determining that the module housing 22 is coupled to the handpiece 24, and the control module controller 31 can be configured to communicate with the charging module 1100 using a second communication protocol in response to determining that the module housing 22 is coupled to the charging module 1100.

[0169] The control module controller 31 can be configured to communicate using a first communication protocol and a second communication protocol by communicating at different transmission rates. For example, the control module controller 31 can be configured to communicate using a first communication protocol by communicating at a first transmission rate, and the control module controller 31 can be configured to communicate using a second communication protocol by communicating at a second transmission rate. 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 a first communication protocol by communicating at 460 kBaud, while it can be configured to communicate using a second communication protocol by communicating at 19.2 kBaud. It should be noted that the control module controller 31 can be configured to communicate with the handpiece 24, the charging module 1100, and the programming tool 1200 using any suitable baud rate.

[0170] The control module controller 31 can be configured to communicate using a first communication protocol and a second communication protocol by communicating using different transmission modes. For example, the control module controller 31 can be configured to communicate using a first communication protocol by communicating using full-duplex transmission, and the control module controller 31 can be configured to communicate using a second communication protocol by communicating using half-duplex transmission. It should be noted that the control module controller 31 can be configured to communicate with the handpiece 24, the charging module 1100, and the programming tool 1200 using any suitable transmission mode, such as full-duplex transmission, half-duplex transmission, and / or unidirectional transmission.

[0171] In one example, the charging adapter 1102 can be configured to convert a communication protocol used by the charging module 1100 to a 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 a communication protocol used by the control module controller 31 to a 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. Referring to FIG. 41 , within the charging adapter 1102, the first adapter communication terminal 1134 and the second adapter communication terminal 1136 are shorted together to enable conversion of the communication protocol used by the charging module 1100 and / or the communication protocol used by the control module controller 31. For example, if the controller is configured to communicate using a first communication protocol by communicating using full-duplex transmission and the charging module 1100 is configured to communicate using a second communication protocol by communicating using 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.

[0172] In another example, communication between the control module controller 31 and the handpiece 24 coupled to the module housing 22, the charging module 1100, or the programming jig 1200 can be initiated by the control module controller 31 or by the handpiece 24 coupled to the module housing 22, the charging module 1100, or the programming jig 1200. 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 jig 1200 can be configured to initiate communication between the control module controller 31 and the programming jig 1200. Specifically, the control module controller 31 can initiate communication by sending a communication signal to the charging module 1100 based on determining that the module housing 22 is coupled to the charging module 1100, and the control module controller 31 can be configured to receive a communication signal from the programming jig 1200 based on determining that the module housing 22 is coupled to the programming jig 1200.

[0173] 44 , the control module controller 31 can return to sleep mode when the analog Hall effect sensor 32 no longer detects the magnetic field generated by the handpiece 24, charging module 1100, or programming tool 1200. For example, if the handpiece 24, charging module 1100, or programming tool 1200 is no longer coupled to the module housing 22, the analog Hall effect sensor 32 can no longer detect the magnetic field generated by the handpiece 24, charging module 1100, or programming tool 1200. If the digital Hall effect sensor 134 is active during the active state, the control module controller 31 can return to sleep mode when the digital Hall effect sensor 134 no longer detects the magnetic field generated by the handpiece 24, charging module 1100, or programming tool 1200.

[0174] The powered surgical tool can include a motor or motor body configured to receive power, including, for example, electrical power or pressurized air, and convert the power into an output torque, which is transmitted through an output shaft. In one embodiment, the powered surgical tool can further include a cannula or can be cannulated.

[0175] In one embodiment, the output shaft of the motor can include a lumen or a hollow center, e.g., extending along the centerline of the output shaft. The lumen can include a first opening at one end of the output shaft and a second opening at a second end of the output shaft. The cannula can include a tube at least partially contained within the lumen extending along the centerline of the output shaft. The cannula can be open at both ends, e.g., to allow a device to pass through the cannula. In this disclosure, a distal portion or direction of a device or component refers to a direction toward the patient. Similarly, a proximal portion or direction of a device or component refers to a direction away from the patient.

[0176] The motor may include electronic components such as electromagnets in the rotor and stator, and electrical wires that electrically connect parts of the motor to other parts of the motor or to terminals that extend outside the motor.

[0177] A powered surgical instrument is provided that includes a motor having a cannula disposed therein, wherein the powered surgical instrument further includes a housing, a sealing plug, and a shaft seal, the sealing plug and the shaft seal configured to prevent liquids utilized in an autoclave process from entering the interior of the powered surgical instrument while allowing a surgical device, such as a K-wire or pin, to pass through the cannula.

[0178] In one embodiment, the attachment to the powered surgical tool may be referred to as a surgical handpiece or handpiece.

[0179] In one embodiment, the pistol grip (or wand or instrument handle) can include a battery and control module, which may be described as a battery and control module (BMC) as described throughout this disclosure.

[0180] FIG. 51 illustrates an exemplary battery and control module 1300 configured as a pistol grip in a front perspective view. The battery and control module 1300 includes a module lumen 1301, or hollow cavity, configured to receive a surgical handpiece or attachment. The module lumen 1301 can be described as a module lumen. FIG. 52 illustrates the battery and control module 1300 of FIG. 51 in a rear perspective view. The battery and control module 1300 includes a cannula access point 1302 configured to allow external access to a cannula disposed in a surgical handpiece that can be attached to the module lumen 1301 of FIG. 51.

[0181] FIG. 53 illustrates a surgical handpiece 1310 configured to be disposed within the module lumen 1301 of the battery and control module 1300 of FIG. 51. The surgical handpiece 1310 includes a housing 1320 configured to house and physically protect the components housed therein, and a mechanism 1312 for physical connection to the battery and control module 1300 at one end and a mechanism 1312 for physical connection to a surgical endpiece attachment at a second end. The second end may include an instrument coupler or may be configured to attach to an instrument coupler. A sealing plug 1360 is shown sealing the end of the surgical handpiece 1310. A cannula lumen 1344 is shown exposed at the end of the surgical handpiece 1310. The powered surgical tool can be described as including a battery and control module 1300 that includes a module lumen 1301 of FIG. 51 into which the surgical handpiece 10 of FIG. 53 is inserted.

[0182] FIG. 54 shows a cross section of the surgical handpiece 1310 of FIG. 53. The surgical handpiece 1310 is shown to include a housing 1320, an internal structural insert 1322, a circuit board 1350, a motor 1330, a cannula 1340, and terminals 1352, 1353 that protrude into the surgical handpiece 1310. The internal structural insert 1322 may be metal, plastic, or other similar material and holds the illustrated components in place relative to the housing 1320. The internal structural insert 1322 may be considered part of the housing 1320. The internal structural insert 1322 may be configured to provide a well-defined location for the circuit board 1350, the cannula 1340, the output shaft 1332, and other portions of the illustrated surgical handpiece 1310 and act as a positioning fixture. The internal structural insert 1322 has an inner diameter at a first proximal end of the surgical handpiece 1310. Terminals 1352, 1353 electronically connect the circuit board 1350 to external electronic components, such as the connectors in the battery and control module 1300 of Figure 51. Power can be supplied to the circuit board 1350 and motor 1330 via terminals 1352, 1353.

[0183] The motor 1330 includes an output shaft 1332 that is mechanically connected to a motor rotor structure 1336 and configured to provide output torque from the motor 1330. The motor further includes a connector board 1338, illustratively including layers of copper, configured to provide electrical connections to portions of the motor 1330. The output shaft 1332 is hollow and includes a lumen 1334 in which a cannula 1340 is disposed. The cannula includes a cannula lumen 1344 at a first proximal end and a second end 1342, which can extend outward from the front or distal end of the surgical handpiece 1310. The cannula 1340 further includes a cannula flange 1346 that serves to position the cannula 1340 and interface with the surgical handpiece's sealing components, i.e., a sealing plug 1360 and a seal 1370.

[0184] Components of the surgical handpiece 1310 internal to the surgical handpiece 1310 may be susceptible to damage or increased wear if exposed to high temperatures and / or liquids during a sterilization or cleaning process. The sealing plug 1360 and seal 1370 are configured to prevent liquids from entering the interior of the surgical handpiece 1310. The sealing plug 1360 may be constructed of a plastic or hard polymer. The sealing plug 1360 may be press-fit into the inner diameter of the internal structural insert 1322, and friction and compression between the sealing plug 1360 and the sidewalls 1362 retains the sealing plug 1360 within the surgical handpiece 1310. The sealing plug 1360 may include a terminal pass-through point 1364 configured to maintain the sealing of the surgical handpiece 1310 while allowing the terminals 1352, 1353 to enter the interior portion of the surgical handpiece 1310.

[0185] The cannula 1340 extends through the sealing plug 1360. A seal 1370 is provided to allow the cannula 1340 to seal against the sealing plug 1360. The seal 1370 is shown as including a cylindrical exterior with a hollow center or seal lumen configured to receive the cannula 1340. The cylindrical shape of the rubberized seal 1370 may have the same longitudinal axis as the cannula 1340. A first sealing surface 1372 is provided on the cylindrical end face of the seal 1370, providing a seal between the seal 1370 and the opposing or mating surface of the sealing plug 1360. A second sealing surface 1374 is provided as an annular ring-shaped surface on the inner diameter of the seal 1370, configured to seal against the outer diameter surface of the cannula 1340. The seal 1370 may be positioned in contact with the cannula flange 1346.

[0186] An instrument coupler may be attached to the output shaft 1332.

[0187] A socket stopper 1380 is disposed around the outside of internal structural insert 1322 and sealing plug 1360. Socket stopper 1380 can be configured to retain sealing plug 1360 within the inner diameter of internal structural insert 1322 if the press fit between sealing plug 1360 and internal structural insert 1322 is broken or loosens.

[0188] FIG. 55 illustrates an embodiment of a powered surgical tool 1400 in which the device housing 1420 of the battery and control module 1410 is designed to provide improved ergonomics and ease of use. The powered surgical tool 1400 further includes a handpiece configured to be removably coupled to the battery and control module 1410 within a handpiece lumen 1430. The battery and control module 1410 can include a battery 1415 housed therein and can further include a circuit board configured to provide functionality for the powered surgical tool 1400, such as selectively powering the handpiece or a unit installed in the handpiece lumen 1430 from the battery 1415. The battery 1415 can include one battery cell or multiple battery cells. The handpiece can include a modular motor and drive train (not shown) and can include additional subcomponents, such as an electrical socket, a gearbox, and features for removably receiving a cutting accessory, including a head. The handpiece can include a modular motor and can be configured to provide energy to a surgical end effector, such as a burr, saw, drill, or other similar device. The handpiece can take the form disclosed in applicant's International Publication No. WO 2013 / 177423, published November 28, 2013, the entire contents of which are incorporated herein by reference, except for certain features of the handpiece described in more detail below.

[0189] The cutting accessory assembly can be unique to each compatible version of the motor and drive train to provide a set of handpieces configured to be selectively and interchangeably coupled to the battery and control module 1410. Any device or accessory applied to a surgical site, whether a sagittal saw blade or a drill bit, may be generally referred to throughout this specification as an energy applicator. In other embodiments, the powered surgical instrument 1400 may be a rotary drill, a reamer, a wire driver, an oscillating or reciprocating saw, an ultrasonic device, or a photonic device. Similarly, the energy applicator may be a drill bit, a burr, a saw, a reamer, an abrasive disk, an ultrasonic cutting tip or catheter insertion tip, a laser, or the like. The type of instrument used is not intended to limit the invention. The motor can be a universal motor capable of interchangeably attaching two or more cutting accessories, as described below. The powered surgical instrument 1400 of the present disclosure may be particularly well-suited for orthopedic surgical procedures involving the arms, hands, legs, feet, mandible, and skull, although other small bone orthopedic and soft tissue procedures are also contemplated.

[0190] The battery and control module 1410 includes at least one battery and a main controller coupled to the printed circuit board assembly, as described in more detail below. The main controller is further configured to communicate with a battery, motor control sensors, and handswitch sensors, which may be part of the battery assembly, and to communicate with the motor when the handpiece is removably 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 handswitch assembly, optionally coupled to the device housing 1420, configured to receive input from a user to operate the powered surgical tool 1400. For example, the handswitch assembly may be spring-loaded and include a handswitch magnet that moves toward the handswitch sensor when the handswitch assembly is actuated. While an example is provided in which the handswitch assembly is coupled to the battery and control module 1410, the handswitch assembly may be detachable and attached to any portion of the battery and control module 1410 and / or the handpiece. Additionally, the handswitch assembly may be part of or attached to the handpiece.

[0191] The battery and control module 1410 includes a barrel 1440 and a handle 1450. The handle 1450 extends downwardly from the barrel 1440. The battery and control module 1410 may be spring-loaded and may have two triggers 1460, 1470 or switches located on the exterior of the battery and control module 1410. Both triggers 1460, 1470 extend forward from the distally directed portion of the handle 1450. A physician can actuate the triggers 1460, 1470 to control operation of the tool unit. The triggers 1460, 1470 may each include a magnet that moves when a user actuates the trigger 1460, 1470, as described in more detail below. The battery and control module 1410 may include a pressure relief valve and a cap.

[0192] FIG. 56 shows a side perspective view of the internal components of the battery and control module 1410, including a pair of trigger sensors 1520, 1530 corresponding to the triggers 1460, 1470 of FIG. 55. The trigger sensors 1520, 1530 can be configured to monitor or detect the presence of or proximity to a magnetic field generated by a permanent magnet, which can be detected through the housing wall. A middle housing 1500 of the device housing 1420 of FIG. 55 is shown. The trigger sensors 1520, 1530 can be located on or included in a printed circuit board 1510. The trigger sensors 1520, 1530 can be Hall effect sensors. The printed circuit board 1510 is disposed inside the handle 1450. In particular, the printed circuit board 1510 is positioned in proximity to the triggers 1460, 1470, thereby enabling the multiple trigger sensors 1520, 1530 to detect the state of the triggers 1460, 1470, such as when a user activates the triggers 1460, 1470.

[0193] A plurality of motor control sensors may be coupled to another or second printed circuit board coupled to the battery and control module 1410. The motor control sensors may be Hall effect sensors. A switching module including a plurality of metal oxide semiconductor field effect transistors (MOSFETs) may also be coupled to the second printed circuit board. While the present disclosure contemplates MOSFETs as the switching elements coupled to the second printed circuit board, other suitable transistors or switching elements may be used. The switching module may be used to control the direction of movement of the handpiece motor, for example, in a forward or reverse direction.

[0194] Figure 57 shows a rear perspective view of a front housing 1600 configured to be assembled, welded, laser attached, or otherwise secured to the handle portion of the mid-housing 1500 of Figure 56. The front housing 1600 is shown to include structures 1620, 1630 configured to receive portions of the triggers 1460, 1470 of Figure 55, as well as springs and other hardware configured to align and enable actuation of the triggers 1460, 1470. Additionally, pockets 1640 or cutout areas are shown configured to receive the trigger sensors 1520, 1530 of Figure 56 and allow the trigger sensors 1520, 1530 to be in close proximity to the triggers 1460, 1470. The pocket 1640 can include a space in which the trigger sensors 1520, 1530 are disposed, while the walls of the front housing 1600 can be disposed between the trigger sensors 1520, 1530 and the triggers 1460, 1470 to seal the battery and control module 1410 and prevent liquids from entering the interior of the battery and control module 1410 while allowing signal communication between the triggers 1460, 1470 and the corresponding trigger sensors 1520, 1530. The front housing 1600 can be intact without any through holes in the area of ​​the structures 1620, 1630 and the pocket 1640. Magnetic interaction between the triggers 1460, 1470 and the corresponding trigger sensors 1520, 1530 allows recognition or signal generation corresponding to depression of the triggers 1460, 1470 while maintaining a sealed housing between the triggers 1460, 1470 and the trigger sensors 1520, 1530.

[0195] 55-57, the printed circuit board 1510 along with the trigger sensors 1520, 1530 can be assembled onto the mid-housing 1500, and the front housing 1600, including the pockets 225 that house the trigger sensors 1520, 1530, can be welded, lasered, or otherwise secured such that the battery and control module 1410 is sealed before the triggers 1460, 1470 are assembled to the battery and control module 1410. It will be appreciated that the triggers 1460, 1470 can be later replaced or refurbished without breaking the seal of the battery and control module 1410.

[0196] FIG. 58 shows a side perspective view of a sealed housing assembly 1610 including a front housing 1600 hermetically welded, lasered, glued, fastened, or otherwise attached to a middle housing 1500. The sealed housing assembly 1610 can include multiple housings that are hermetically joined together and configured to house components together. The housings of the disclosed battery and control module 1410 can be constructed of polymers, and welding can refer to a joining process, such as a vibration welding process, in which contacting 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, according to an autoclave process, without the heated liquids of the sterilization process penetrating the interior of the sealed housing assembly 1610 and contacting the internal components, such as the circuit board and battery 1415.

[0197] Figure 59 shows a side perspective view of the sealed housing assembly 1610 of Figure 58 with attached triggers 1460, 1470. Trigger 1460 is shown in an at least partially undepressed state, and trigger 1470 is shown in an at least partially depressed state.

[0198] FIG. 60 shows the sealed housing assembly 1610 and triggers 1460, 1470 of FIG. 59 in a disassembled state. A trigger hardware component 1700 is shown including a spring, a trigger lock translation plate, and positioning hardware configured to allow assembly and selective actuation of the triggers 1460, 1470. The trigger hardware component 1700 can include a face plate 1710 and screws 1720 configured for installation and removal, allowing the triggers 1460, 1470 to be easily attached and later replaced. The triggers 1460, 1470 can be held in place by the face plate 1710 and screws 1720. Each of the triggers 1460, 1470 is shown to include a round or cylindrical stem portion 1462, 1472. The sealed housing assembly 1610 is shown to include a pair of trigger bores 1612, 1614 configured to receive the stem portions 1462, 1472, respectively. The stem portions 1462, 1472 can be described as configured to engage with the trigger lumens 1612, 1614.

[0199] 61 shows a side cross-sectional view of a portion of the sealed housing assembly 1610 and the triggers 1460, 1470. Also shown is the circuit board 1510. The triggers can each include magnets 1730, 1732 useful for providing control signals to the trigger sensors 1520, 1530 of FIG.

[0200] Figure 62 shows a front cross-sectional view of a portion of the sealed housing assembly 1610 and the trigger 1470. The trigger 1470 is shown to include a magnet 1730. Also shown is the corresponding trigger sensor 1530 of Figure 56. Also shown is the screw boss feature 1618 configured to receive the screw 1720 of Figure 60.

[0201] The triggers 1460, 1470 can be selectively depressed to actuate the surgical instrument 1400 of Figure 55. The triggers 1460, 1470 of Figure 60 can include stem portions 1462, 1472 configured to be mounted in corresponding trigger lumens 1612, 1614. In some examples, air trapped between the triggers 1460, 1470 and the walls of the trigger lumens 1612, 1614 can prevent free movement of the triggers 1460, 1470 relative to the sealed housing assembly 1610.

[0202] Figure 63 shows a front perspective view of a portion of a sealed housing assembly 1610 including multiple trigger vent cutouts 1660, 1670. Each of the trigger vent cutouts 1660, 1670 may include a channel formed in the wall of the sealed housing assembly 1610 configured to release air from behind each of the triggers 1460, 1470 of Figure 60 when each of them is installed or depressed. The trigger vent cutouts 1660, 1670 allow air to be released from behind each of the triggers 1460, 1470 while maintaining the sealed housing assembly 1610 as a sealed unit.

[0203] 64 shows a front cross-sectional view of a portion of the sealed housing assembly 1610 including the stem portions 1462, 1472 and respective trigger vent cutouts 1660, 1670. The stem portions 1462, 1472 can fit snugly against the surface of the respective trigger lumen 1612, 1614, while the trigger vent cutouts 260A, 260B provide a path for air to flow from behind the triggers 1460, 1470 of FIG.

[0204] FIG. 65 is a flowchart illustrating a method 1800 of operating a powered surgical tool. The method 1800 is provided utilizing the battery and control module 1410 of FIG. 55, although other examples of surgical tools may be utilized in accordance with the method 1800. The method 1800 begins at step 1802. In step 1804, the method 1800 includes providing a battery and control module 1410 including a hermetic housing assembly 1610. The hermetic housing assembly 1610 encloses a printed circuit board 1510 including at least one trigger sensor 1520 and includes at least one trigger lumen 1612 configured to receive a trigger 1460. In step 1806, the method 1800 continues, including installing at least one trigger 1460 within the trigger lumen 1612, the trigger 1460 including a stem portion 1462 having at least one magnet 1530 configured to interact with the trigger sensor 1520 without compromising the hermeticity of the hermetic housing assembly 1610. Method 1800 ends at step 1808. Numerous additional and / or alternative method steps are contemplated, and method 1800 is not intended to be limited to the examples provided herein.

[0205] FIG. 66 is a flow chart illustrating a method 1900 for servicing a powered surgical tool. Method 1900 is provided utilizing the battery and control module 1410 of FIG. 55, although other examples of surgical tools may be utilized in accordance with method 1900. Method 1900 begins at step 1902. In step 1904, method 1900 includes providing a battery and control module 1410 including a sealed housing assembly 1610. The sealed housing assembly 1610 encloses 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. In step 1906, method 1900 continues, including removing the trigger 1460 from the battery and control module 1410 without compromising the seal of the sealed housing assembly 1610. In step 1908, method 1900 ends. Numerous additional and / or alternative method steps are contemplated, and method 1900 is not intended to be limited to the examples provided herein.

[0206] The broad teachings of the present disclosure can be implemented in a variety of forms. Thus, while the present disclosure includes certain examples, the true scope of the disclosure should not be limited thereto, as other variations will become apparent from a study of the drawings, the specification, and the following claims. It should be understood that one or more steps within a method can be performed in a different order (or simultaneously) without altering the principles of the present disclosure. Furthermore, although each of the examples is described above as having certain features, any one or more of the features described with respect to any example of the present disclosure can be implemented in and / or combined with features of any of the other examples, even if the combination is not explicitly described. In other words, the described examples are not mutually exclusive, and permutations of one or more examples are within the scope of the present disclosure.

[0207] Spatial and functional relationships between elements (e.g., between controllers, circuit elements, semiconductor layers, etc.) are described using various terms such as "connected," "engaged," "coupled," "adjacent," "next to," "on top of," "above," "below," and "disposed." Unless explicitly stated as "direct," when the relationship between a first element and a second element is described in the above disclosure, the relationship may be a direct relationship where no other intervening elements exist between the first element and the second element, or it may be an indirect relationship where one or more intervening elements (spatial or functional) exist between the first element and the second element.

[0208] As used herein, the phrase "at least one of A, B, and C" should be interpreted to mean (A or B or C) using a non-exclusive logical OR, and not to mean "at least one of A, at least one of B, at least one of C." The term "subset" does not necessarily require a proper subset. In other words, a first subset of a first set may be coextensive (equal to) the first set.

[0209] In the diagrams, the direction of the arrow, as indicated by the arrowhead, generally indicates the flow of information (e.g., data or instructions) that is the subject of the discussion. For example, an arrow may point from element A to element B if element A and element B exchange various information and the information transmitted from element A to element B is relevant to the discussion. This unidirectional arrow does not imply that other information is not transmitted from element B to element A. Furthermore, for information sent from element A to element B, element B may send element A a request for that information or an acknowledgment of the request.

[0210] In this application, including in the definitions below, the term "circuitry" may be substituted for the term "controller" or "module." The term "controller" may refer to, be a part of, or include an application specific integrated circuit (ASIC), a programmable system on a chip (PSoC), digital, analog, or mixed analog / digital discrete circuitry, a digital, analog, or mixed analog / digital integrated circuit, a combinational logic circuit, a field programmable gate array (FPGA), a processor circuit (shared, dedicated, or group) that executes code, a memory circuit (shared, dedicated, or group) that stores code to be executed by the processor circuitry, other suitable hardware components that provide the described functionality, or a combination of some or all of the above, such as in a system on a chip.

[0211] The controller can include one or more interface circuits having one or more transceivers. In some examples, the interface circuit can implement a wired or wireless interface to connect to a local area network (LAN) or a wireless personal area network (WPAN). Examples of LANs include the Institute of Electrical and Electronics Engineers (IEEE) Standard 802.11-2016 (also known as the WIFI wireless networking standard) and IEEE Standard 802.3-2015 (also known as the ETHERNET wired networking standard). Examples of WPANs include the BLUETOOTH wireless networking standard from the Bluetooth Special Interest Group and IEEE Standard 802.15.4.

[0212] Controllers can communicate with other controllers using interface circuits. While this disclosure may depict controllers logically communicating directly with other controllers, in various embodiments, the controllers may actually communicate through a communication system. The communication system may include physical and / or virtual networking equipment such as hubs, switches, routers, gateways, and transceivers. In some embodiments, the communication system connects to or traverses a wide area network (WAN) such as the Internet. For example, the communication system may include multiple LANs connected to each other via the Internet or point-to-point leased lines using technologies including multiprotocol label switching (MPLS) and virtual private networks (VPNs).

[0213] In various embodiments, the functionality of a controller may be distributed among multiple controllers connected via a communication system. For example, multiple controllers may implement the same functionality distributed by a load balancing system. In a further example, the functionality of a controller may be split between a server (also known as a remote or cloud) controller and a client (or user) controller.

[0214] Some or all of the hardware functions of the controller can be defined using a hardware description language, 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 fabricate and / or program hardware circuits. In some embodiments, some or all of the functions of the controller can be defined by a language, such as IEEE 1666-2005 (commonly referred to as "SystemC"), which encompasses both code and hardware descriptions, as described below.

[0215] 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 encompasses a single processor circuit that executes some or all code from multiple controllers. The term group processor circuit encompasses a processor circuit that executes some or all code from one or more controllers in combination with additional processor circuits. References to multiple processor circuits encompass multiple processor circuits on separate dies, multiple processor circuits on a single die, multiple cores of a single processor circuit, multiple threads of a single processor circuit, or combinations of the above. The term shared memory circuit encompasses a single memory circuit that stores some or all code from multiple controllers. The term group memory circuit encompasses a memory circuit that stores some or all code from one or more controllers in combination with additional memory.

[0216] The term memory circuit is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as by carrier waves), and thus the term computer-readable medium can be considered tangible and non-transitory. Non-limiting examples of non-transitory computer-readable media are non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or masked read-only memory circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), 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).

[0217] The apparatus and methods described in this application can be implemented, in part or entirely, 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 functional blocks and flowchart elements described above can serve as software specifications that can be translated into a computer program by the routine work of a skilled engineer or programmer.

[0218] A computer program includes processor-executable instructions stored on at least one non-transitory computer-readable medium. A computer program may also include or rely on stored data. A computer program may encompass a basic input / output system (BIOS) that interacts with hardware in a special-purpose computer, device drivers that interact with specific devices in a special-purpose computer, one or more operating systems, user applications, background services, background applications, etc.

[0219] A computer program may include (i) written 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, (v) source code compiled and executed by a just-in-time compiler, etc. By way of example only, the source code may be written using syntax from languages ​​including C, C++, C#, Objective-C, Swift, Haskell, Go, SQL, R, Lisp, Java®, Fortran, Perl, Pascal, Curl, OCaml, JavaScript®, HTML5 (Hypertext Markup Language Fifth Edition), Ada, ASP (Active Server Pages), PHP (PHP: Hypertext Preprocessor), Scala, Eiffel, Smalltalk, Erlang, Ruby, Flash®, Visual Basic®, Lua, MATLAB®, SIMULINK®, and Python®.

Claims

1. a handpiece including a motor and an instrument coupler, the handpiece defining at least one of a rail and a slot, the handpiece further defining a receiving surface; A battery and control module, a device housing including the other of the rail and the slot, the rail and the slot configured such that the rail is slidable within the slot to allow connection between the handpiece and the battery and control module, the device housing further defining a void space; a rechargeable battery module disposed within the void space; a printed circuit board assembly including a controller configured to adjust power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a condition of the motor; at least three conductive terminals extending through the device housing to establish an electrical connection between the printed circuit board assembly and the handpiece; and a battery and control module including A powered surgical instrument comprising:

2. The powered surgical tool of claim 1 , wherein the handpiece defines a cannula and the device housing is non-cannulated.

3. The powered surgical tool of claim 1 or 2, wherein the battery and control module includes a safety vent.

4. The powered surgical tool of claim 1 , wherein the motor is an electric motor.

5. The powered surgical tool of claim 1 , wherein the motor sensor is further defined as a Hall Effect sensor.

6. The powered surgical tool of claim 1 , wherein the handpiece includes a memory device electrically connected to at least one of the at least three conductive terminals.

7. The powered surgical tool of claim 1 , wherein a distal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

8. 8. The powered surgical tool of claim 1, wherein a portion of a proximal end face of the handpiece is exposed when the handpiece is coupled to the battery and control module.

9. 9. The powered surgical tool of claim 1, wherein the battery and control module includes a latch assembly including a locking member and a biasing member, the biasing member positioned to bias the locking member toward the receiving surface.

10. a handpiece including a motor and an instrument coupler, said handpiece defining a cannulated portion; A battery and control module, a device housing defining a void space; a rechargeable battery module disposed within the void space; a printed circuit board assembly including a controller configured to adjust power drawn from the rechargeable battery module based on user input, the printed circuit board assembly further comprising a motor sensor configured to output a motor sensor signal representative of a condition of the motor; at least three conductive terminals extending through the device housing to establish an electrical connection between the printed circuit board assembly and the handpiece; a battery and control module including: Equipped with The powered surgical tool, wherein the battery and control module is cannulated.

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

12. 12. The powered surgical tool of claim 10 or 11, wherein the motor is an electric motor.

13. The powered surgical tool of claim 10, wherein the motor sensor is further defined as a Hall effect sensor.

14. The powered surgical tool of claim 10, wherein the handpiece includes a memory device electrically connected to at least one of the at least three conductive terminals.

15. 15. The powered surgical tool of claim 10, wherein a 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. 1. A surgical handpiece coupled to a battery and a control module, comprising: Housing and An appliance connector; an electric motor disposed within the housing; a rotor defining an axis, said rotor coupled to said electric motor and said implement link; a rigid circuit board including a controller, the rigid circuit board disposed within the housing and oriented perpendicular to the axis of the rotor; a plurality of terminals extending through the housing and engaging the rigid circuit board; A surgical handpiece comprising:

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. 19. The surgical handpiece of claim 17 or 18, wherein the surgical handpiece defines a longitudinal axis, the surgical handpiece defining a cannula that circumscribes the longitudinal axis.

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

21. The surgical handpiece of claim 20, wherein the aperture and the cannula are coaxial.

22. 1. A surgical handpiece coupled to a battery and a control module, comprising: Housing and An appliance connector; an electric motor disposed within the housing; a rotor defining an axis, said rotor coupled to said electric motor and said implement link; a circuit board including 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 a plurality of terminals extending through the housing and engaging the flexible portion of the circuit board; A surgical handpiece comprising:

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 handpiece including a motor; A battery and control module, a device housing having a recess that removably receives the handpiece, the device housing defining a void space; a rechargeable battery module disposed within the void space; a first printed circuit board disposed within the void space and having rigidity; a rigid second printed circuit board disposed within the void space, the second printed circuit board coupled to the first printed circuit board, the second printed circuit board and the first printed circuit board arranged in a stacked configuration, and a plurality of motor control sensors connected to the second printed circuit board; a controller configured to adjust power drawn from the rechargeable battery module based on user input, the controller being mounted on one of the first printed circuit board and the second printed circuit board; and a battery and control module including: A powered surgical instrument comprising:

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

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

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

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

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

30. 30. The powered surgical tool of any one of claims 24-29, wherein the battery and control module further comprises a board mount, the board mount including one of a set of cutouts or a set of protrusions, the device housing defining the other of the set of cutouts or the set of protrusions, the set of protrusions engaging the set of cutouts to prevent movement of the board mount with multiple degrees of freedom relative to the device housing.

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

32. 32. The powered surgical tool of any one of claims 24 to 31, wherein the board mount includes the set of protrusions, each of the set of protrusions defining a receiving portion for securing one of the plurality of motor control sensors.

33. 31. The powered surgical tool of claim 30, wherein the motor includes a plurality of magnets, and the device housing includes the set of notches defining a series of notch peaks and notch valleys, the innermost surfaces of the notch peaks being farther from the motor magnets than the innermost surfaces of the notch valleys.

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

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

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

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

38. 38. The powered surgical tool of claim 37, wherein the second printed circuit board includes at least four sides and the board mount contacts no more than two sides of the second printed circuit board.

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

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

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

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

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

44. 44. The powered surgical tool of any one of claims 24 to 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 handpiece including a motor; A battery and control module, a device housing having a recess that removably receives the handpiece, the device housing defining a void space; a rechargeable battery module disposed within the void space; a printed circuit board assembly disposed within 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; a controller configured to adjust power drawn from the rechargeable battery module based on user input, the controller being mounted on the printed circuit board assembly; and a battery and control module including: A powered surgical instrument comprising:

46. 46. ​​The powered surgical tool of claim 45, wherein the battery and control module further comprises a board mount, the board mount including one of a set of notches or a set of protrusions, the device housing defining the other of the set of notches or the set of protrusions, the set of protrusions engaging the set of notches to prevent the rigid portion of the printed circuit board assembly from moving in more than one degree of freedom relative to the device housing.

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

48. 47. The powered surgical tool according to claim 46, wherein the board mount includes the set of protrusions, each of the set of protrusions defining a receiving portion for securing one of the plurality of motor control sensors.

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

50. a handpiece including a motor, the motor including a plurality of magnets; A control module comprising: a device housing that removably receives the handpiece, the device housing defining a void space; a first terminal; a sensor configured to provide a sensor signal, the sensor 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; a control module including: A powered surgical instrument comprising:

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

52. 52. The powered surgical tool of claim 50 or 51, wherein the first set of sensors are digital Hall effect sensors.

53. 53. The powered surgical tool of any one of claims 50 to 52, further comprising a second set of sensors, said second set of sensors being analog Hall effect sensors.

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

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

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

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

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

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

60. 60. The powered surgical tool of claim 59, wherein the hand piece includes a memory device and data terminals in electrical communication with the memory device, the data terminals configured to connect with the second terminals of the control module when the hand piece is received in the recess.

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

62. 62. The powered surgical tool of any one of claims 50 to 61, wherein the motor includes a motor rotor, laminations surrounding the rotor of the motor, and a plurality of magnets surrounding the rotor, a portion of the plurality of magnets extending axially beyond the laminations.

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

64. 1. A powered surgical tool having a pencil grip type configuration, a plastic housing defining an integral mounting base, the integral mounting base defining a first aperture and a second aperture; a first pin and a second pin extending through the first aperture and the second aperture, respectively, the first pin defining a pivot axis and a pivot surface, the first pin and the second pin defining a press-fit engagement with one another; a lever pivotally connected to the pivot surface of the first pin; A powered surgical instrument comprising:

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

66. 66. The powered surgical tool of claim 65, further comprising a torsion spring including a coil, a first leg, and a second leg, the first leg and the second leg extending from opposite ends of the coil, the coil surrounding the first pin.

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

68. a handpiece including a motor, the plastic housing defining a recess for removably receiving the handpiece, the plastic housing defining a void space; a printed circuit board disposed within the void space; a rechargeable battery module disposed within the void space, the lever configured to receive input from a user to cause power to be drawn from the rechargeable battery module and provided to the motor, the powered surgical instrument having a pencil grip configuration; Furthermore, 66. The powered surgical tool of claim 65, wherein the plastic housing includes a controller configured to regulate power drawn from the rechargeable battery module based on movement of the lever.

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

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

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

72. 72. The powered surgical instrument of claim 71, wherein the lever includes an activation-safety switch slidably mounted to the lever, a magnet attached to the activation-safety switch, a lever extension movably coupled to the lever, and the hand switch sensor is a Hall effect sensor.

73. a housing defining a cavity; a circuit board disposed within the cavity of the housing for controlling operation of an electric motor; a rechargeable battery module disposed within the cavity; at least three motor pins spaced apart from one another to define an array of motor pins that extend through the housing and out of the cavity to establish electrical connections between the circuit board and the electric motor, a hermetically sealed housing-terminal interface being defined by the housing and the at least three motor pins; a routing mechanism disposed about the at least three motor pins, the routing mechanism defining a plurality of 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 another end of the wire connected to the circuit board, each of the wire terminals including a first end and a second end opposite the first end, the first end connected to one of the at least three wires and the second end configured to electrically engage one of the motor pins, each of the wire terminals positioned within one of the channels of the routing mechanism; A powered surgical instrument comprising:

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

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

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

77. 77. The powered surgical tool of claim 76, wherein the routing mechanism defines a rim, the rim defining the plurality of channels, the rim surrounding the at least three motor pins.

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

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

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

81. 80. The powered surgical tool of claim 79, wherein the first end of the at least one of the wire terminals defines a plurality of arms, the arms being crimped into engagement with the first wire end.

82. 82. The powered surgical tool of claim 81, wherein the second end of the wire terminal defines a cylindrical cavity, the cylindrical cavity being disposed about the motor pin.

83. a handpiece including a motor; a module housing configured to couple with one of the handpiece and the charging module, each of the handpiece and the charging module configured to generate a magnetic field; 1. A printed circuit board assembly comprising: a digital Hall effect sensor configured to sense a magnetic field; an analog Hall effect sensor configured to sense a magnetic field; A controller, a sleep state in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; and an active state in which the analog Hall effect sensor is active; a controller configured to operate with a printed circuit board assembly including: Equipped with the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting a magnetic field; the controller is configured to determine whether the module housing is coupled to one of the handpiece and the charging module based on the magnetic field sensed by the analog Hall effect sensor.

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

85. 85. The powered surgical tool of claim 84, wherein the analog Hall effect sensor receives more power from the rechargeable battery in the active state than the digital Hall effect sensor receives in the sleep state.

86. The controller In response to determining that the module housing is coupled to the handpiece, communicating with the handpiece using a first communication protocol; In response to determining that the module housing is coupled to the charging module, communicating with the charging module using a second communication protocol.

86. The powered surgical tool of any one of claims 83 to 85, configured to

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

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

89. 89. The powered surgical tool of any one of claims 83 to 88, wherein the controller is configured to send a communication signal to the hand piece based on determining that the module housing is coupled to the hand piece.

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

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

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

93. 1. A system for identifying a device coupled to a powered surgical tool, comprising: a handpiece configured to generate a magnetic field; a charging module configured to generate a magnetic field; 1. A powered surgical instrument comprising: a module housing configured to couple to one of the handpiece and the charging module; 1. A printed circuit board assembly comprising: a digital Hall effect sensor configured to sense a magnetic field; an analog Hall effect sensor configured to sense a magnetic field; A controller, a sleep state in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; and an active state in which the analog Hall effect sensor is active; a controller configured to operate with a printed circuit board assembly including: a powered surgical instrument comprising: Equipped with the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting a magnetic field; The system, wherein the controller is configured to determine whether the module housing is coupled to one of the handpiece and the charging module based on the magnetic field sensed by the analog Hall effect sensor.

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

95. the handpiece further includes a motor including a first rotor magnet and a second rotor magnet, each of the first rotor magnet and the second rotor magnet configured to generate a magnetic field to cause rotation of the motor; the first analog Hall effect sensor, the second analog Hall effect sensor, and the third analog Hall effect sensor are configured to sense the magnetic fields generated by the first rotor magnet and the second rotor magnet, respectively; 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; 95. The system of claim 94, wherein the controller is configured to determine that the module housing is coupled to the handpiece based on the first analog Hall effect sensor, the second analog Hall effect sensor, and the third analog Hall effect sensor sensing the magnetic fields generated by the first rotor magnet and the second rotor magnet.

96. further comprising a programming tool including a magnet configured to generate a first magnetic field; the charging module includes a magnet configured to generate a second magnetic field; the analog Hall effect sensor is configured to sense a magnetic field by sensing the magnitude of the magnetic field; 94. The system of claim 93, wherein the position of the magnet on the programming fixture and the position of the magnet on the charging module are selected such that the magnitude of the first magnetic field sensed by the analog Hall effect sensor is different from the magnitude of the second magnetic field sensed by the analog Hall effect sensor.

97. further comprising a programming tool including a magnet configured to generate a first magnetic field; the charging module includes a magnet configured to generate a second magnetic field; the analog Hall effect sensor is configured to sense a magnetic field by sensing the polarity of the magnetic field; 94. The system of claim 93, wherein the polarity of the magnet of the programming fixture and the polarity of the magnet of the charging module are selected such that the polarity of the first magnetic field sensed by the analog Hall effect sensor is different from the polarity of the second magnetic field sensed by the analog Hall effect sensor.

98. a first handpiece including a motor; a second handpiece including a motor; a module housing configured to couple with one of the first handpiece and the second handpiece, each of the first handpiece and the second handpiece configured to generate a magnetic field; 1. A printed circuit board assembly comprising: a digital Hall effect sensor configured to sense a magnetic field; an analog Hall effect sensor configured to sense a magnetic field; A controller, a sleep state in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; and an active state in which the analog Hall effect sensor is active; a controller configured to operate with a printed circuit board assembly including: Equipped with the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting a magnetic field; the controller is configured to determine whether the module housing is coupled to one of the handpiece and the charging module based on the magnetic field sensed by the analog Hall effect sensor.

99. 1. A system for identifying a device coupled to a powered surgical tool, comprising: a handpiece configured to generate a magnetic field; a charging module coupled to a charging adapter, the charging adapter configured to generate a magnetic field; 1. A powered surgical instrument comprising: a module housing configured to couple to one of the handpiece and the charging module; 1. A printed circuit board assembly comprising: a digital Hall effect sensor configured to sense a magnetic field; an analog Hall effect sensor configured to sense a magnetic field; A controller, a sleep state in which the digital Hall effect sensor is active and the analog Hall effect sensor is inactive; and an active state in which the analog Hall effect sensor is active; a controller configured to operate with a printed circuit board assembly including: a powered surgical instrument comprising: Equipped with the controller is configured to transition from the sleep state to the active state based on the digital Hall effect sensor detecting a magnetic field; The system, wherein the controller is configured to determine whether the module housing is coupled to one of the handpiece and the charging module based on the magnetic field sensed by the analog Hall effect sensor.

100. 1. 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: a charger having a recess; An adapter, a charger protrusion configured to be received in the recess, the recess including a surface facing a first direction; a module protrusion configured to be received in the module housing to enable the charger to provide power to the rechargeable battery module via the adapter, the module protrusion extending in a direction different from the first direction; an adapter comprising: A charging system comprising:

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

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

103. Each recess includes a width; each of the modular projections includes a width; 103. The charging system of claim 102, wherein the sum of the widths of the module protrusions is less than the width of the recesses.

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

105. 1. A charging system for charging a rechargeable battery module of a first powered surgical instrument of a pencil grip type and a rechargeable battery module of a second powered surgical instrument of a pistol grip type, wherein the first powered surgical instrument and the second powered surgical instrument each include a module housing configured to receive a handpiece, the charging system comprising: a charger including a recess; An adapter, a charger protrusion configured to be received in the recess; A module protrusion, to the module housing of the first powered surgical tool so as to enable the charger to provide power to the rechargeable battery module of the first powered surgical tool via the adapter; and to the module housing of the second powered surgical tool so as to enable the charger to provide power to the rechargeable battery module of the second powered surgical tool via the adapter. a module projection configured to receive the module; an adapter including A charging system comprising:

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

107. the module projection includes a first portion configured to be received in the module housing of the first powered surgical tool; a second portion configured to be received in the modular housing of the second powered surgical tool; 107. The charging system of claim 106, comprising:

108. the modular housing of the first powered surgical tool includes a first radius; the modular housing of the second powered surgical tool includes a second radius different from the first radius; the first portion of the module projection includes a cylindrical shape sized to be received in the module housing of the first powered surgical tool; 108. The charging system of claim 107, wherein the second portion of the module projection includes a cylindrical shape sized to be received in the module housing of the second powered surgical tool.

109. The module protrusion is a first latch disposed on the first portion, the first latch configured to engage an interface of the module housing of the first powered surgical tool; and a second latch disposed on the second portion, the second latch configured to engage an interface of the module housing of the second powered surgical tool; and 108. The charging system of claim 107, comprising:

110. a charger including a recess; An adapter, a charger protrusion configured to be received in the recess; a module protrusion; a magnet disposed on the module protrusion, the magnet configured to generate a magnetic field; and an adapter including 1. A first powered surgical instrument, comprising: 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 a first distance from the first end of the module housing; a first controller configured to transition from a sleep state to an active state based on the first Hall sensor detecting a magnetic field, the first controller configured to communicate with the charger when the first controller is in the active state; a first powered surgical instrument including: a second powered surgical tool, 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 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 detecting a magnetic field, the second controller configured to communicate with the charger when the second controller is in the active state; a second powered surgical instrument including: A charging system comprising:

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

112. 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 charger and a battery configured to receive power from the charger in response to contacting the charger; An adapter, a charger protrusion configured to contact the charger; a module protrusion; a magnet disposed on the module protrusion, the magnet configured to generate a magnetic field; and an adapter including 1. A powered surgical instrument comprising: a module housing configured to receive the module protrusion; Hall sensors and a controller configured to transition from a sleep state to an active state based on the Hall sensor detecting a magnetic field, the controller configured to communicate with the charger when the controller is in the active state; a powered surgical instrument including: A charging system comprising:

114. 114. The charging system of claim 113, wherein the controller is configured to communicate using a first communication protocol, the charger is configured to communicate using a second communication protocol, and 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. 115. The charging system of claim 114, wherein the charger includes a charger power terminal and a charger communication terminal, 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, the module protrusion includes a first adapter communication terminal and a second adapter communication terminal that communicate with the adapter communication contact, and 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 through the adapter.

116. 116. The charging system of claim 115, wherein the controller is configured to communicate using the first communication protocol by communicating using full-duplex transmission, the charger is configured to communicate using the second communication protocol by communicating using 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.

117. 1. A surgical handpiece coupled to a battery and a control module, comprising: Housing and an electric motor including a rotor disposed within the housing and including an output shaft defining a longitudinal axis, the output shaft configured to be coupled at a first end to the electric motor and at a second end to a surgical instrument, the output shaft defining a lumen centered about the longitudinal axis of the output shaft; and a cannula partially disposed within the lumen 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, the cannula passing through the sealing plug; a seal disposed around the exterior of the cannula; a plurality of terminals extending through the sealing plug; A surgical handpiece comprising:

118. 118. The surgical handpiece of claim 117, wherein the second distal end includes an instrument coupler.

119. the bore centered about the longitudinal axis of the output shaft is a first bore; the seal includes a cylindrical shape having a second lumen; 119. The surgical handpiece of claim 117 or 118, wherein the cannula is disposed within the second lumen.

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

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

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

123. the housing includes an internal structural insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece; 123. The surgical handpiece of claim 122, wherein the sealing plug is press fit within the inner diameter of the internal structural insert.

124. 124. The surgical handpiece of claim 123, further comprising a socket stopper disposed around the exterior of the internal structural insert and the sealing plug, the socket stopper configured to retain the sealing plug within the inner diameter of the internal structural insert.

125. 125. The surgical handpiece of any one of claims 117 to 124, wherein the seal is positioned in contact with the cannula flange.

126. 1. A surgical handpiece, comprising: Housing and an electric motor including a rotor disposed within the housing and including an output shaft defining a longitudinal axis, the output shaft configured to be coupled at a first end to the electric motor and attached at a second end to a surgical instrument, the output shaft defining a lumen centered about the longitudinal axis of the output shaft; and a cannula partially disposed within the lumen 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, the cannula passing through the sealing plug; a seal disposed around the exterior of the cannula; a plurality of terminals extending through said sealing plug; a surgical handpiece including: a battery and control module including a recess configured to receive the surgical handpiece; A powered surgical instrument comprising:

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

128. 128. The powered surgical tool of claim 126 or 127, wherein the second distal end includes an tool coupler.

129. the seal includes a cylindrical shape having a hollow center; 129. The powered surgical tool of any one of claims 126 to 128, wherein the cannula is disposed within the hollow center of the seal.

130. the seal includes a first sealing surface on the cylindrical end face abutting a mating surface on the sealing plug; 130. The powered surgical instrument of claim 129, wherein the seal includes a second sealing surface including an annular ring on an inner diameter of the seal abutting an outer surface of the cannula.

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

132. the housing includes an internal structural insert disposed within the housing and including an inner diameter at the first proximal end of the surgical handpiece; 132. The powered surgical instrument of claim 131, wherein the sealing plug is mounted within the inner diameter of the internal structural insert by a press fit.

133. 133. The powered surgical instrument of claim 132, further comprising a socket stopper disposed about an exterior of the internal structural insert and the sealing plug, the socket stopper configured to retain the sealing plug within the inner diameter of the internal structural insert.

134. 131. The powered surgical tool of any one of claims 126 to 130, wherein the seal is disposed in contact with the cannula flange.

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

136. A battery and control module, 1. A sealed housing assembly comprising: a printed circuit board including at least one trigger sensor; a plurality of housings hermetically joined to one another and configured to house the printed circuit board and the at least one trigger sensor therein; at least one trigger lumen configured to receive a trigger, the at least one trigger sensor being disposed proximate to the at least one trigger lumen; a sealed housing assembly including: at least one trigger mounted to the battery and control module within the at least one trigger lumen, the at least one trigger including a stem portion configured to engage the at least one trigger lumen, the stem portion including at least one magnet configured to interact with the at least one trigger sensor; Battery and control module including A powered surgical instrument comprising:

137. the at least one trigger lumen includes a trigger vent cutout formed in a wall of the at least one trigger lumen; the trigger vent cutout is formed in a surface of the wall without compromising the sealing of the sealed housing assembly; 137. The powered surgical instrument according to claim 136, wherein the trigger vent cutout is configured to allow air to escape behind the at least one trigger when the at least one trigger is depressed or seated.

138. the at least one trigger is retained within the at least one trigger bore by a screw and a face plate; 138. The powered surgical instrument of claim 136 or 137, wherein the screw and the front plate allow the at least one trigger to be replaced without compromising the seal of the sealed housing assembly.

139. the sealed housing assembly includes two trigger bores; 139. The powered surgical tool of any one of claims 136 to 138, further comprising two triggers.

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

141. 141. The powered surgical instrument of any one of claims 136 to 140, wherein the sealed housing assembly further comprises a handpiece lumen configured to receive a handpiece including a modular motor configured to provide energy to a surgical end effector.

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

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

144. 1. A method of operating a powered surgical tool, comprising: providing a battery and control module including a sealed housing assembly, said housing assembly enclosing a printed circuit board including at least one trigger sensor and at least one trigger lumen configured to receive a trigger; installing at least one trigger within the trigger lumen, the trigger including a stem portion having at least one magnet configured to interact with the trigger sensor without compromising the hermeticity of the hermetic housing assembly; A method comprising:

145. 1. A method of repairing a powered surgical tool, comprising: providing a battery and control module including a sealed housing assembly, said housing assembly enclosing a printed circuit board including at least one trigger sensor, said battery and control module further including a trigger having a magnet; removing the trigger from the battery and control module without compromising the sealing integrity of the sealed housing assembly; A method comprising:

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