Filter for energy pathway of monopolar surgical instrument - Patent application

Abstract

The electrosurgical system includes an instrument, an RF energy generator, and two grounding pads. The instrument includes an electrode and a conductive shield configured to collect capacitively coupled current induced by application of RF energy to tissue by the electrode. A first electrical lead couples the first grounding pad to a ground return of the conductive shield and to the generator. The ground return is configured to divert a first portion of the capacitively coupled current through the first electrical lead to the generator. A second electrical lead couples a second grounding pad to a ground return of the conductive shield and to the generator. The ground return is configured to divert a second portion of the capacitively coupled current through the second electrical lead to the generator. The first and second portions of the capacitively coupled current are substantially equal.

Description

[Background technology]

[0001] Various ultrasonic surgical instruments include an end effector with a blade element that vibrates at ultrasonic frequencies to cut and / or seal tissue (e.g., by denaturing proteins within tissue cells). These instruments contain one or more piezoelectric elements that convert electrical power into ultrasonic vibrations, which are transmitted along an acoustic waveguide to the blade element. Examples of ultrasonic surgical instruments and related concepts are disclosed in U.S. Patent Application Publication No. 2006 / 0079874, published April 13, 2006, now abandoned, entitled "Tissue Pad for Use with an Ultrasonic Surgical Instrument," the disclosures of which are incorporated herein by reference in their entireties; U.S. Patent Application Publication No. 2007 / 0191713, published August 16, 2007, now abandoned, entitled "Ultrasonic Device for Cutting and Coagulating," the disclosures of which are incorporated herein by reference in their entireties; and U.S. Patent Application Publication No. 2008 / 0200940, published August 21, 2008, now abandoned, entitled "Ultrasonic Device for Cutting and Coagulating," the disclosures of which are incorporated herein by reference in their entireties.

[0002] Some instruments are operable to seal tissue by applying radiofrequency (RF) electrosurgical energy to the tissue. Examples of such devices and related concepts are disclosed in U.S. Patent No. 7,354,440, entitled "Electrosurgical Instrument and Method of Use," issued April 8, 2008, the disclosure of which is incorporated herein by reference in its entirety, and U.S. Patent No. 7,381,209, entitled "Electrosurgical Instrument," issued June 3, 2008, the disclosure of which is incorporated herein by reference in its entirety.

[0003] Some instruments are capable of applying both ultrasonic and RF electrosurgical energy to tissue. Examples of such instruments are described in US Patent No. 9,949,785, entitled "Ultrasonic Surgical Instrument with Electrosurgical Feature," issued April 24, 2018, the disclosure of which is incorporated herein by reference in its entirety, and US Patent No. 8,663,220, entitled "Ultrasonic Electrosurgical Instruments," issued March 4, 2014, the disclosure of which is incorporated herein by reference in its entirety.

[0004] In some scenarios, it may be preferable to directly grasp and manipulate the surgical instrument by one or more hands of one or more human operators. Additionally, or alternatively, it may be preferable to have the surgical instrument controlled via a robotic surgical system. Examples of robotic surgical systems and associated instrumentation are described in U.S. Pat. No. 10,624,709, entitled "Robotic Surgical Tool with Manual Release Lever," issued May 2, 2019, the disclosure of which is incorporated herein by reference in its entirety; U.S. Pat. No. 9,314,308, entitled "Robotic Ultrasonic Surgical Device With Articulating End Effector," issued April 19, 2016, the disclosure of which is incorporated herein by reference in its entirety; U.S. Pat. No. 9,125,662, entitled "Multi-Axis Articulating and Rotating Surgical Tools," issued September 8, 2015, the disclosure of which is incorporated herein by reference in its entirety; and U.S. Pat. No. 9,125,662, entitled "Robotically-Controlled Surgical Device with Articulating End Effector," issued September 2, 2014, the disclosure of which is incorporated herein by reference in its entirety. No. 8,820,605, entitled "Ultrasonic Surgical Instruments," the disclosure of which is incorporated herein by reference in its entirety; U.S. Patent Application Publication No. 2019 / 0201077, entitled "Interruption of Energy Due to Inadvertent Capacitive Coupling," published July 4, 2019, the disclosure of which is incorporated herein by reference in its entirety; U.S. Patent Application Publication No. 2012 / 0292367, entitled "Robotically-Controlled End Effector," published November 11, 2012, the disclosure of which is incorporated herein by reference in its entirety; and U.S. Patent Application No. 16 / 556,661, entitled "Ultrasonic Surgical Instrument with a Multi-Planar Articulating Shaft Assembly," filed August 30, 2019, the disclosure of which is incorporated herein by reference in its entirety.

[0005] While several surgical instruments and systems have been made and used, it is believed that no one prior to the inventors has made or used the invention as recited in the appended claims. [Brief explanation of the drawings]

[0006] While this specification concludes with claims particularly pointing out and distinctly claiming the present technology, it is believed that the present technology will be better understood from the following description of certain specific embodiments read in conjunction with the accompanying drawings, in which like reference numerals identify the same elements. [Figure 1] FIG. 1 shows a schematic diagram of one embodiment of a robotic surgical system. [Figure 2] 1 shows a schematic diagram of one embodiment of a robotic surgical system in use on a patient. [Figure 3] 1A-1C show schematic diagrams of examples of components that may be incorporated into a surgical instrument. [Figure 4] FIG. 1 shows a side view of one embodiment of a handheld surgical instrument. [Figure 5] FIG. 1 illustrates a perspective view of one embodiment of an end effector operable to apply ultrasonic energy to tissue. [Figure 6] FIG. 1 illustrates a perspective view of one embodiment of an end effector operable to apply bipolar RF energy to tissue. [Figure 7] 1 shows a schematic diagram of one embodiment of a surgical instrument operable to apply monopolar RF energy to tissue. [Figure 8] 1 shows a perspective view of one embodiment of an articulation portion that may be incorporated into a shaft assembly of a surgical instrument. [Figure 9] 1 shows a side view of a portion of a shaft assembly that may be incorporated into a surgical instrument, with the housing components of the shaft shown in cross section to reveal the internal components of the shaft. [Figure 10] 10A-10C show cross-sectional end views of another shaft assembly that may be incorporated into a surgical instrument. [Figure 11]1 shows a schematic diagram of a portion of another shaft assembly that may be incorporated into a surgical instrument. [Figure 12] FIG. 2 shows a perspective view of one embodiment of a surgical instrument that can be incorporated into the robotic surgical system of FIG. [Figure 13] FIG. 13 shows a top view of the interface drive assembly of the instrument of FIG. 12. [Figure 14] FIG. 13 shows a cross-sectional side view of the articulation portion of the shaft assembly of the instrument of FIG. [Figure 15] 1 shows a perspective view of another embodiment of a handheld surgical instrument, with the modular shaft assembly separated from the handle assembly. [Figure 16] 1 shows a schematic diagram of one embodiment of a surgical instrument operable to apply monopolar RF energy to tissue and provide a return path for irregular electrical energy. [Figure 17] 17 shows a schematic diagram of the surgical instrument of FIG. 16 illustrating a first alternative configuration of an exemplary return path. [Figure 18] 17 shows a schematic diagram of the surgical instrument of FIG. 16 illustrating a second alternative configuration of the exemplary return path. [Figure 19] 1 shows a schematic diagram of another embodiment of a surgical instrument operable to apply monopolar RF energy to tissue. [Figure 20] 1 shows a flow diagram of an exemplary method for monitoring energy loss in a surgical instrument operable to apply RF energy to tissue. [Figure 21] FIG. 1 shows a schematic diagram of an example of a dual energy system including an instrument operable to apply bipolar and monopolar energy to tissue. [Figure 22] FIG. 10 shows a schematic diagram of another embodiment of a dual-energy system including an instrument operable to apply bipolar and monopolar energy to tissue. [Figure 23] 1 shows a side view of a portion of another shaft assembly that may be incorporated into a surgical instrument, with the housing components of the shaft shown in cross section to reveal the internal components of the shaft. [Figure 24]1 shows a side view of a portion of another shaft assembly that may be incorporated into a surgical instrument, with the housing components of the shaft shown in cross section to reveal the internal components of the shaft. [Figure 25] 1 shows a flow diagram of an exemplary method for monitoring characteristics of mechanical components of a surgical instrument operable to apply RF energy to tissue. [Figure 26] 1 shows a schematic diagram of a first exemplary electrical contact array having features for protecting the electrical contacts. [Figure 27] FIG. 10 shows a schematic diagram of a second exemplary electrical contact array having features for protecting the electrical contacts. [Figure 28] FIG. 10 shows a schematic diagram of a third exemplary electrical contact array having features for protecting the electrical contacts.

[0007] The drawings are not intended to be limiting in any manner, and it is contemplated that various embodiments of the technology may be embodied in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings, which are incorporated in and form a part of this specification, illustrate several aspects of the technology and, together with the description, serve to explain the principles of the technology, although it is understood that the technology is not limited to the precise arrangements shown. DETAILED DESCRIPTION OF THE INVENTION

[0008] The following description of specific examples of the present technology should not be used to limit its scope. Other examples, features, aspects, embodiments, and advantages of the present technology will become apparent to those skilled in the art from the following description, which is, by way of example, one of the best modes contemplated for carrying out the present technology. As will be understood, the technology described herein is capable of other different and obvious aspects, all without departing from the technology. Therefore, the drawings and descriptions should be regarded as illustrative in nature, and not as limiting.

[0009] It will be further understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein can be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Therefore, the teachings, expressions, embodiments, examples, etc. described below should not be considered in isolation from one another. Various suitable ways in which the teachings herein can be combined will be readily apparent to those skilled in the art in light of the teachings herein. Such modifications and variations are intended to be within the scope of the claims.

[0010] For clarity of this disclosure, the terms "proximal" and "distal" are defined herein relative to a human or robotic surgical instrument operator. The term "proximal" refers to the location of an element closer to a human or robotic surgical instrument operator and further from a surgical end effector of the surgical instrument. The term "distal" refers to the location of an element closer to a surgical end effector of the surgical instrument and further from a human or robotic surgical instrument operator. Additionally, the terms "upper," "lower," "top," "bottom," "upper," and "lower" are used with respect to the examples and associated figures and are not intended to unnecessarily limit the invention described herein.

[0011] I. Examples of Robotic Surgical Systems As mentioned above, in some surgical procedures, it may be desirable to utilize a robotically controlled surgical system. Such a robotically controlled surgical system may include one or more surgical instruments that are robotically controlled and driven via one or more users, either in the same operating room or remote from the operating room. FIG. 1 illustrates one example of various components that may be incorporated into a robotic surgical system 10. The system 10 in this example includes a console 20, a monopolar RF electrosurgical instrument 40, a bipolar RF electrosurgical instrument 50, and an ultrasonic surgical instrument 60. While FIG. 1 illustrates all three instruments 40, 50, and 60 being coupled to the console 20 simultaneously, there may be usage scenarios in which only one or two of the instruments 40, 50, and 60 are coupled to the console 20 simultaneously. Furthermore, there may be usage scenarios in which various other instruments are coupled to the console (20) in addition to, or as an alternative to, one or more of the instruments (40, 50, 60) coupled to the console (20).

[0012] The monopolar RF electrosurgical instrument (40) of this example includes a body (42), a shaft (44) extending distally from the body (42), and an end effector (46) at the distal end of the shaft (44). The body (42) is configured to couple with a robotic arm (not shown in FIG. 1 ) of the system (10), which is operable to position and orient the monopolar RF electrosurgical instrument (40) relative to a patient. In variations in which the monopolar RF electrosurgical instrument (40) includes one or more mechanically driven components (e.g., jaws on the end effector (46), an articulation portion of the shaft (44), a rotation portion of the shaft (44), etc.), the body (42) may include various components operable to translate one or more mechanical drive inputs from the robotic arm into movement of the one or more mechanically driven components of the monopolar RF electrosurgical instrument (40).

[0013] As also shown in FIG. 1 , body 42 is coupled to corresponding port 22 of console 20 via cable 32. Console 20 is operable to supply power to monopolar RF electrosurgical instrument 40 via port 22 and cable 32. In some variations, port 22 is dedicated to driving monopolar RF electrosurgical instruments, such as monopolar RF electrosurgical instrument 40. In some other variations, port 22 is operable to drive various types of instruments (including, for example, instruments 50, 60, etc.). In some such variations, console 20 is operable to automatically detect the type of instrument 40, 50, 60 coupled to port 22 and adjust the power profile to port 22 accordingly. Additionally or alternatively, the console (20) may adjust the power profile to the port (22) based on a selection made by an operator via the console (20) manually identifying the type of instrument (40, 50, 60) coupled to the port (22).

[0014] The shaft 44 is operable to support the end effector 46 and provides one or more wires or other pathways for electrical communication between the base 42 and the end effector 46. Thus, the shaft 44 is operable to transfer power from the console 20 to the end effector 46. The shaft 44 may also include various mechanically movable components, including, but not limited to, rotating segments, articulating joints, and / or other types of mechanically movable components as will be apparent to those skilled in the art in view of the teachings herein.

[0015] The end effector 46 of this example includes an electrode operable to apply monopolar RF energy to tissue. Such an electrode may be incorporated into a sharp blade, a needle, a flat surface, some other atraumatic structure, or any other suitable type of structure as would be apparent to one skilled in the art in light of the teachings herein. The end effector 46 may also include various other types of components, including, but not limited to, grasping jaws, etc.

[0016] The system 10 of this embodiment further includes a grounding pad 70 coupled to a corresponding port 28 of the console 20 via a cable 38. In some variations, the grounding pad 70 is incorporated into a patch or other structure that is affixed to the patient's skin (e.g., on the patient's thigh). In some other variations, the grounding pad 70 is positioned underneath the patient (e.g., between the patient and the operating table). In either case, the grounding pad 70 can serve as a return path for monopolar RF energy applied to the patient via the end effector 46. In some variations, the port 28 is a dedicated ground return port. In some other variations, the port 28 is a multi-purpose port that is either automatically designated as a ground return port when the console 20 detects coupling between the grounding pad 70 and the port 28, or manually designated as a ground return port via an operator using a user input feature of the console 20.

[0017] The bipolar RF electrosurgical instrument (50) of this example includes a body (52), a shaft (54) extending distally from the body (52), and an end effector (56) at the distal end of the shaft (54). Each of these components (52, 54, 56) may be configured and operative in accordance with the above description of the corresponding components (42, 44, 46) of the monopolar RF electrosurgical instrument (50), except that the end effector (56) of this example is operable to apply bipolar RF energy to tissue. Accordingly, the end effector (56) includes at least two electrodes configured to cooperate with one another to apply bipolar RF energy to tissue. The bipolar RF electrosurgical instrument (50) is coupled to the console (20) via a cable (34), which is further coupled to a port (24) of the console (20). Port 24 may be dedicated to powering a bipolar RF electrosurgical instrument, or it may be a multi-purpose port whose output is determined based on either automatic detection of a bipolar RF electrosurgical instrument 50 or operator selection via the user input feature of console 20.

[0018] The ultrasonic surgical instrument (60) of this example includes a body (62), a shaft (64) extending distally from the body (62), and an end effector (66) at the distal end of the shaft (64). Each of these components (62, 64, 66) may be configured and operative in accordance with the above description of the corresponding components (42, 44, 46) of the monopolar RF electrosurgical instrument (50), except that the end effector (66) of this example is operable to apply ultrasonic energy to tissue. Accordingly, the end effector (66) includes an ultrasonic blade or other ultrasonic vibration element. Additionally, the base (62) includes an ultrasonic transducer (68) operable to generate ultrasonic vibrations in response to electrical power, and the shaft (64) includes an acoustic waveguide operable to transmit the ultrasonic vibrations from the transducer (68) to the end effector (66).

[0019] Ultrasonic surgical instrument 60 is coupled to console 20 via cable 36, which is further coupled to port 26 of console 20. Port 26 may be dedicated to powering the ultrasonic electrosurgical instrument, or port 26 may be a multi-purpose port whose output is determined either by automatic detection of ultrasonic surgical instrument 60 or by operator selection via a user input feature of console 20.

[0020] While FIG. 1 illustrates monopolar RF, bipolar RF, and ultrasound capabilities provided via three separate, dedicated instruments (40, 50, 60), some variations may include instruments operable to apply two or more of monopolar RF, bipolar RF, or ultrasound energy to tissue. In other words, two or more of such energy modalities may be combined into a single instrument. An example illustrating how such different modalities may be integrated into a single device is described in U.S. Patent Application Publication No. 2017 / 0202591, published July 20, 2017, entitled "Modular Battery Powered Handheld Surgical Instrument with Selective Application of Energy Based on Tissue Characterization," the disclosure of which is incorporated herein by reference in its entirety. Other examples will be apparent to those skilled in the art in view of the teachings herein.

[0021] FIG. 2 illustrates one embodiment of a robotic surgical system 150 relative to a patient P on a table 156. In this embodiment, the system 150 includes a control console 152 and a drive console 154. The console 152 is operable to receive user inputs from an operator, and the drive console 154 is operable to translate these user inputs into movement of a set of robotic arms 160, 170, 180. In some variations, the consoles 152, 154 collectively form an equivalent of the console 20 described above. While the consoles 152, 154 are shown as separate units in this embodiment, in some other embodiments, the consoles 152, 154 may actually be combined into a single unit.

[0022] The robotic arms (160, 170, 180) extend from the drive console (154) in this example. In some other variations, the robotic arms (160, 170, 180) are integrated into the platform (156) or some other structure. Each robotic arm (160, 170, 180) has a corresponding drive interface (162, 172, 182). In this example, the three drive interfaces (162, 172, 182) are coupled to one single instrument assembly (190). In some other scenarios, each drive interface (162, 172, 182) is coupled to a separate respective instrument. By way of example only, the drive interfaces (162, 172, 182) may be coupled to an instrument body, such as the bodies (42, 52, 62) of the instruments (40, 50, 60) described above. In either case, the robotic arms (160, 170, 180) may be operable to move the instruments (40, 50, 60, 190) relative to the patient (P) and to actuate any mechanically driven components of the instruments (40, 50, 60, 190). The robotic arms (160, 170, 180) may also include features that provide a path for the transmission of power to the instruments (40, 50, 60, 190). For example, the cables (32, 34, 36) may be at least partially integrated into the robotic arms (160, 170, 180). In some other variations, the robotic arms (160, 170, 180) may include features that secure, but do not necessarily integrate, the cables (32, 34, 36). As yet another variation, the cables (32, 34, 36) may simply remain separate from the robotic arms (160, 170, 180). Other suitable features and configurations that may be used to form the robotic surgical system (10, 150) will be apparent to those skilled in the art in view of the teachings herein.

[0023] In a robotic surgical system, such as the robotic surgical system 10, 150, each port 22, 24, 26, 28 may include multiple electrical features that provide inputs and outputs between the console 20, 152 and the robotic arms 160, 170, 180 and / or instruments 40, 50, 60, 190. These electrical features may include sockets, pins, contacts, or various other features that are in close proximity to one another. In some scenarios, this proximity may pose a risk of undesired crossing of power or signals from one electrical feature to another, resulting in equipment failure, equipment damage, sensor errors, and / or other undesirable consequences. Additionally, or alternatively, this proximity may pose a risk of generating electrical potentials between nearby components or creating capacitive coupling between electrical features. Such capacitive coupling may result in undesirable consequences such as reduced power, reduced signal, signal interference, patient injury, and / or other undesirable consequences. Therefore, it may be desirable to provide features at ports (22, 24, 26, 28) to prevent or otherwise address such occurrences.

[0024] Similarly, each robotic arm (160, 170, 180), each cable (32, 34, 36, 38), and / or each instrument (40, 50, 60, 190) may include multiple wires, traces within rigid or flexible circuits, and other electrical features in close proximity to one another. Such electrical features may also be in close proximity to other components that are not intended to provide a path for electrical communication but are nevertheless formed from conductive materials. Such conductive mechanical features may include moving components (e.g., drive cables, drive bands, gears, etc.) or stationary components (e.g., chassis or frame members, etc.). This proximity may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to the conductive mechanical feature, which may result in equipment failure, equipment damage, sensor errors, and / or other undesirable consequences. Additionally or alternatively, this proximity may pose a risk of generating electrical potentials between nearby components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. Such capacitive coupling can result in undesirable consequences such as power reduction, signal reduction, signal interference, patient injury, and / or other undesirable consequences. Therefore, it may be desirable to provide features within the robotic arms (160, 170, 180), cables (32, 34, 36, 38), and / or instruments (40, 50, 60, 190) to prevent or otherwise address such occurrences.

[0025] II. Handheld Surgical Instrument Examples In some procedures, a surgeon may prefer to use a handheld surgical instrument in addition to, or instead of, using a robotic surgical system (10, 150). Figure 3 shows one example of various components that may be incorporated into a handheld surgical instrument (100). In addition to the teachings below, the instrument (200) may be constructed and operative in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2017 / 0202608, entitled "Modular Battery Powered Handheld Surgical Instrument Containing Elongated Multi-Layered Shaft," published July 20, 2017, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. The instrument (100) of this example includes an end effector (102), an ultrasonic transducer (104), a generator (106), control circuitry (108), a speaker (110), a position sensor (112), a force sensor (114), a visual display (116), and a trigger (118). In some variations, the end effector (102) is disposed at the distal end of a shaft (not shown in FIG. 3), and the other components (104, 106, 108, 110, 112, 114, 116, 118) are incorporated into a handle assembly (not shown in FIG. 3) at the proximal end of the shaft. Some variations may also provide some of the components (104, 106, 108, 110, 112, 114, 116, 118) as separate capital equipment. For example, the generator (106), speaker (110), and / or visual display (116) may be incorporated into separate capital equipment coupled with the instrument (100).

[0026] The end effector (102) may be configured and operable similarly to the end effectors (46, 56, 66) described above, such that the end effector (102) may be operable to apply monopolar RF energy, bipolar RF energy, or ultrasonic energy to tissue. The transducer (104) may be configured and operable similarly to the transducer (68). The generator (106) may be operable to provide power as needed to drive the transducer (68) and / or to provide RF energy via the end effector (102). In variations in which the generator (106) is incorporated into the handle assembly of the instrument (106), the generator (106) may include one or more battery cells or the like. The control circuit (108) may include one or more microprocessors and / or various other circuit components that may be configured to provide signal processing and other electronic aspects of the operability of the instrument (100). The position sensor (112) may be configured to sense the position and / or orientation of the instrument (102). In some variations, the control circuit (108) is configured to vary the maneuverability of the instrument (102) based on data from the position sensor (112). The force sensor (114) is operable to sense one or more force parameters associated with use of the instrument (100). Such force parameters may include a force applied to the instrument (100) by an operator, a force applied to tissue by the end effector (102), or other force parameters as will be apparent to those skilled in the art in view of the teachings herein. In some variations, the control circuit (108) is configured to vary the maneuverability of the instrument (102) based on data from the force sensor (114). In some variations, one or both of the sensors (112, 114) may be incorporated into the end effector (102). Additionally or alternatively, one or both of sensors (112, 114) may be incorporated into a shaft assembly (not shown) of instrument (100).Variations of the instrument (100) may also incorporate various other types of sensors (e.g., in addition to or instead of sensors (112, 114) in the end effector (102), in the shaft assembly, and / or elsewhere in the instrument (100)).

[0027] The trigger 118 is operable to control aspects of the operation of the end effector 102, such as movement of the pivoting jaws, translation of the cutting blade, etc. The speaker 110 and visual display 116 are operable to provide the operator with audible and visual feedback related to the operation of the instrument 100. The above-described components 102, 104, 106, 108, 110, 112, 114, 116, 118 of the instrument 100 are illustrative examples, and components 102, 104, 106, 108, 110, 112, 114, 116, 118 may be modified, substituted, supplemented, or omitted as desired.

[0028] FIG. 4 illustrates one example of a possible form of instrument (100). In particular, FIG. 4 illustrates a handheld instrument (200). In addition to the teachings below, instrument (200) may be constructed and operative in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2017 / 0202591, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. In this example, instrument (200) includes a handle assembly (210), a shaft assembly (220), and an end effector (230). Handle assembly (210) includes a pivotable trigger (212), a first trigger button (214), a second trigger button (216), and an articulation control section (218). Shaft assembly (220) includes a rigid shaft section (222) and an articulation section (224). The end effector (230) is distal to the articulation portion (224) and includes an upper jaw (232) and a lower jaw (234).

[0029] By way of example only, the handle assembly (210) may include one or more of the components (104, 106, 108, 110, 112, 114, 116, 118) described above. The trigger (212) may be operable to pivot the upper jaw (232) toward the lower jaw (234) (e.g., to grasp tissue between the jaws (232, 234)). The trigger buttons (214, 216) may be operable to initiate delivery of energy (e.g., RF energy and / or ultrasonic energy) through the end effector (230). The articulation control (218) is operable to drive deflection of the shaft assembly (220) at the articulation section (224), thereby driving lateral deflection of the end effector (230) either away from or toward a central longitudinal axis defined by the rigid shaft section (222). The end effector (230) may include one or more electrodes operable to apply monopolar and / or bipolar RF energy to tissue. Additionally, or alternatively, the end effector (230) may include an ultrasonic blade operable to apply ultrasonic energy to tissue. In some variations, the end effector (230) is operable to apply two or more of monopolar RF energy, bipolar RF energy, or ultrasonic energy to tissue. Other suitable features and functionality that may be incorporated into the end effector (230) will be apparent to those skilled in the art in view of the teachings herein.

[0030] The instruments (150, 200) may include multiple wires, traces in rigid or flexible circuits, and other electrical features in close proximity to one another. Such electrical features may be located within the handle assembly (210), shaft assembly (220), and / or end effector (230). Such electrical features may also be in close proximity to other components that are not intended to provide a path for electrical communication but are nonetheless formed from conductive materials. Such conductive mechanical features may include moving components (e.g., drive cables, drive bands, gears, etc.) or stationary components (e.g., chassis or frame members, etc.). This proximity may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to the conductive mechanical feature, which may result in instrument failure, instrument damage, sensor errors, and / or other undesirable consequences. Additionally, or alternatively, this proximity may pose a risk of generating electrical potentials between nearby components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. Such capacitive coupling can result in undesirable consequences such as power reduction, signal reduction, signal interference, and / or other undesirable consequences, and therefore, it may be desirable to provide features within the instrument (150, 200) to prevent or otherwise address such occurrences.

[0031] III. Further Examples of Surgical Instrument Components The following description relates to examples of different features that may be incorporated into any of the various instruments (40, 50, 60, 100, 190, 200) described above. While these examples are provided separately from one another, features described in any of the following examples may be combined with features described in other examples described below. Accordingly, the features described below may be combined in various permutations, as will become apparent to those skilled in the art in light of the teachings herein. Similarly, various ways in which the features described below may be incorporated into any of the various instruments (40, 50, 60, 100, 190, 200) described above will become apparent to those skilled in the art in light of the teachings herein. The features described below may be incorporated into robotically controlled surgical instruments (40, 50, 60, 190) and / or handheld surgical instruments (100, 200).

[0032] A. Example of ultrasonic end effector 5 illustrates a portion of one embodiment of an ultrasonic instrument 300, including a shaft assembly 310 and an end effector 320. The end effector 320 includes an upper jaw 322 and an ultrasonic blade 326. The upper jaw 322 is operable to pivot toward the ultrasonic blade 326, thereby compressing tissue between a clamp pad 324 of the upper jaw 322 and the ultrasonic blade 326. When the ultrasonic blade 326 is activated with ultrasonic vibrations, the ultrasonic blade 326 can cut and seal tissue compressed against the clamp pad 324. By way of example only, the end effectors 66, 102, 230 can be configured and operable similarly to the end effector 320.

[0033] As described above, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to a conductive mechanical feature. Additionally, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of generating electrical potentials between adjacent components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. In the context of the instrument (300), such a risk may arise with respect to the acoustic waveguide in the shaft assembly (310) that leads to the ultrasonic blade (326), because the acoustic waveguide may be formed of a conductive material. Additionally, the instrument (300) may include one or more sensors in the shaft assembly (310) and / or end effector (320) and one or more electrodes and / or other electrical features in the end effector (320). Other components of device (350) that may present the risks discussed above will become apparent to those skilled in the art in view of the teachings herein.

[0034] B. Bipolar RF End Effector Example FIG. 6 shows a portion of one embodiment of a bipolar RF instrument (350), including a shaft assembly (360) and an end effector (370). The end effector (370) includes an upper jaw (372) and a lower jaw (374). The jaws (372, 374) are pivotable toward and away from each other. The upper jaw (372) includes a first electrode surface (376), and the lower jaw (374) includes a second electrode surface (378). When tissue is compressed between the jaws (372, 374), the electrode surfaces (376, 378) can be activated with opposite polarities, thereby applying bipolar RF energy to the tissue. This bipolar RF energy can seal the compressed tissue. In some variations, the end effector (370) further includes a translating knife member (not shown) operable to cut the tissue compressed between the jaws (372, 374). Some variations of end effector (370) may also be operable to apply monopolar RF energy to tissue, such as by activating only one electrode surface (376, 378) in cooperation with a grounding pad (e.g., grounding pad (70)), or by activating both electrode surfaces (376, 378) with a single polarity. By way of example only, end effector (64, 102, 230) may be configured and operable similarly to end effector (370).

[0035] As described above, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to a conductive mechanical feature. Additionally, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of generating electrical potentials between adjacent components or capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. In the context of the instrument (350), such risks may arise with respect to the electrode surfaces (376, 378) and wires or other electrical features that extend along the shaft assembly (360) to reach the electrode surfaces (376, 378). Additionally, the instrument (350) may include one or more sensors within the shaft assembly (360) and / or end effector (370) and one or more electrodes and / or other electrical features within the end effector (370). Other components of device (350) that may present the risks discussed above will become apparent to those skilled in the art in view of the teachings herein.

[0036] C. Examples of Monopolar Surgical Instrument Features FIG. 7 illustrates one embodiment of a monopolar RF energy delivery system (400) including a generator (410), a delivery instrument (420), and a grounding pad assembly (440). In addition to the teachings below, the instrument (420) may be constructed and operable in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2019 / 0201077, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. The generator (410) may be operable to deliver monopolar RF energy to the instrument (420) via a cable (430) coupled to the generator (410) via a port (414). In some variations, the port (414) includes an integrated sensor. By way of example only, such a sensor within the port (414) may be configured to monitor whether excess or inductive energy is being emitted from the generator (410) and / or monitor other characteristics of the energy delivered from the generator (410) via the port (414). The instrument (420) includes a body (422), a shaft (424), a sensor (426), and a distal electrode (428) configured to contact the patient (P) and thereby apply monopolar RF energy to the patient (P). By way of example only, the sensor (426) may be configured to monitor whether excess or inductive energy is radiating from the instrument (420). Based on a signal from the sensor (426), a control module within the generator (410) may passively throttle the ground return from the grounding pad assembly (440) based on data from the sensor.

[0037] In some variations, the grounding pad assembly (440) includes one or more resistively conductive grounding pads that provide direct contact between the patient's (P) skin and one or more metal components of the grounding pad. In other variations, the grounding pad assembly (440) includes a capacitively coupled grounding pad that includes a gel material interposed between the patient (P) and a ground return plate. In this example, the grounding pad assembly (440) is positioned below the patient (P) and is coupled to the generator (410) via the cable (432) through ports (416, 434). Either or both of the ports (416, 434) may include an integrated sensor. By way of example only, such a sensor in either or both of the ports (416, 434) may be configured to monitor whether excess or inductive energy is radiating from the grounding pad assembly (440).

[0038] As discussed above, instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to a conductive mechanical feature. Additionally, instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of generating electrical potentials between adjacent components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. In the context of instrument (420), such risks may arise with respect to sensor (426), distal electrode (428), and / or any other electrical components within instrument (420). Other components of instrument (420) that may present the above-mentioned risks will be apparent to those skilled in the art in view of the teachings herein. Such risks may be greater in variations of instrument (420) that are dedicated to the delivery of monopolar RF energy than in the context of bipolar RF instruments, such as instrument (350). This is because dedicated monopolar RF instruments may lack a ground return path that could otherwise prevent or mitigate the above risks.

[0039] D. Example of an articulation in a shaft assembly FIG. 8 illustrates a portion of an instrument 500 including a shaft 510 having an articulating portion 520. In addition to the teachings below, the instrument 500 may be constructed and operable in accordance with at least some of the teachings of U.S. Patent Application Publication No. 2017 / 0202591, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. In this example, an end effector 550 is positioned at the distal end of the articulating portion 520. The articulating portion 520 includes multiple segments 522 and is operable to deflect the end effector 550 laterally away from and toward the central longitudinal axis of the shaft 510. Multiple wires 540 extend through the shaft 510 and along the articulating portion 520 to the end effector 550, thereby delivering power to the end effector 550. By way of example only, the end effector 550 may be operable to deliver monopolar and / or bipolar RF energy to tissue, as described herein. Multiple push-pull cables 542 also extend through the articulation portion 520. The push-pull cables 542 may be coupled to an actuator (e.g., similar to the articulation control portion 218) to drive articulation of the articulation portion 520. The segments 522 are configured to maintain separation between and provide structural support for the wires 540 and the push-pull cables 542 along the length of the articulation portion 520. The articulation portion 520 of this embodiment also defines a central passage 532. By way of example only, the central passage 532 may house an acoustic waveguide (e.g., in variations in which the end effector 550 further includes an ultrasonic blade), may provide a path for fluid communication, or may serve any other suitable purpose. Alternatively, the central passage (532) may be omitted.

[0040] As described above, the instruments 150, 200 may include electrical features and / or conductive mechanical features that may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to a conductive mechanical feature. Additionally, the instruments 150, 200 may include electrical features and / or conductive mechanical features that may pose a risk of generating electrical potentials between adjacent components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. In the context of the instrument 500, such risks may arise with respect to the wire 540 and / or the push-pull cable 542. Additionally, the instrument 500 may include one or more sensors within the shaft assembly 510 and / or end effector 550, and may include one or more electrodes and / or other electrical features within the end effector 550. Other components of the instrument 500 that may present the above-mentioned risks will be apparent to those skilled in the art in light of the teachings herein.

[0041] E. Example of wiring to the end effector 9 illustrates a portion of an instrument 600 including a shaft 610 having a first articulating segment 612 and a second articulating segment 614. In addition to the teachings below, the instrument 600 may be constructed and operative in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2017 / 0202605, entitled "Modular Battery Powered Handheld Surgical Instruments and Methods Therefor," published July 20, 2017, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. In this example, an end effector 620 is positioned at the distal end of the second articulating segment 614. The end effector 620 in this example includes a pair of jaws 622, 624 operable to pivot toward and away from each other to grasp tissue. In some variations, one or both of the jaws (622, 624) include one or more electrodes operable to apply RF energy to tissue, as described herein. Additionally, or alternatively, the end effector (620) may include an ultrasonic blade and / or various other features. The segments (612, 614) may be operable to pivot relative to the shaft (610) and relative to each other, thereby deflecting the end effector (620) laterally away from or toward the central longitudinal axis of the shaft (610).

[0042] The instrument 600 of this example further includes a first set of wires 630 extending through the shaft 610, a second set of wires 632 extending through the shaft 610 and both segments 612, 614, and a third set of wires 634 extending further through the shaft 610 and both segments 612, 614. The wire sets 630, 632, 634 may be operable to control movement of the segments 612, 614 relative to the shaft 610. For example, power may be transmitted along one or more of the wire sets 630, 632, 634 to selectively engage or disengage a corresponding clutch mechanism, thereby enabling lateral deflection of one or both of the segments 612, 614 relative to the shaft 610 and / or rotation of one or both of the segments 612, 614 relative to the shaft 610. Alternatively, power may be transmitted along one or more of the wire sets (630, 632, 634) to drive corresponding solenoids, motors, or other features to actively drive lateral deflection of one or both of the segments (612, 614) relative to the shaft (610) and / or rotation of one or both of the segments (612, 614) relative to the shaft (610). In variations in which the end effector (620) is operable to apply RF energy to tissue, in addition to the wire sets (630, 632, 634), one or more additional wires may extend along the shaft (610) and the segments (612, 614).

[0043] As discussed above, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to a conductive mechanical feature. Additionally, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of generating electrical potentials between adjacent components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. In the context of the instrument (600), such risks may arise with respect to the wire sets (630, 632, 634), the electrical components to which the wire sets (630, 632, 634) are coupled, and / or other features that drive lateral deflection of one or both of the segments (612, 614) relative to the shaft (610). Additionally, instrument 600 may include one or more sensors within shaft assembly 610 and / or end effector 620, and may include one or more electrodes and / or other electrical features within end effector 620. Other components of instrument 600 that may present the above-mentioned risks will be apparent to those skilled in the art in view of the teachings herein.

[0044] F. Example of a Sensor in a Shaft Assembly FIG. 10 illustrates one example of another shaft assembly (700) that may be incorporated into any of the various instruments (40, 50, 60, 100, 190, 200, 300, 350, 400, 500, 600) described herein. In addition to the teachings below, the shaft assembly (700) may be constructed and operative in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2017 / 0202608, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. The shaft assembly (700) of this example includes an outer shaft (710), a first inner shaft (712), and a second inner shaft (714). A support member (716) extends diametrically across the interior of the second inner shaft (714). By way of example only, the support member (716) may include a circuit board, a flex circuit, and / or various other electrical components. In this embodiment, multiple sensors (720, 722, 724) are positioned on the support member (716). A magnet (730) is embedded in the outer shaft (710) that is operable to rotate about the inner shafts (712, 714).

[0045] In some variations, rotation of the outer shaft (710) about the inner shaft (712, 714) drives rotation of an end effector (not shown) located at the distal end of the shaft assembly (700) about the longitudinal axis of the shaft assembly (700). In some other variations, rotation of the outer shaft (710) about the inner shaft (712, 714) drives lateral deflection of the end effector either away from or toward the longitudinal axis of the shaft assembly (700). Alternatively, rotation of the outer shaft (710) about the inner shaft (712, 714) may have any other result. In either case, the sensors (720, 722, 724) may be configured to track the position of the magnet (730) and thereby determine the rotational position (742) of the outer shaft (710) relative to the fixed axis (740). Thus, sensors (720, 722, 724) may collectively function as a position sensor, such as position sensor (112) of instrument (100).

[0046] FIG. 11 illustrates one example of an alternative shaft assembly (750) that may be incorporated into any of the various instruments (40, 50, 60, 100, 190, 200, 300, 350, 400, 500, 600) described herein. In addition to the teachings below, the shaft assembly (750) may be constructed and operative in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2017 / 0202608, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. The shaft assembly (750) of this example includes a plurality of coaxially positioned proximal shaft segments (752, 754, 756) and a distal shaft segment (764). The distal shaft segment (764) is pivotally coupled to the proximal shaft segment (752) via a pin (762) to form an articulation joint (760). An end effector (not shown) may be positioned distal to the distal shaft segment (764), such that the articulation joint (760) may be utilized to deflect the end effector laterally away from or toward the central longitudinal axis defined by the proximal shaft segments (752, 754, 756). A flex circuit (758) extends along the shaft segments (752, 754, 756, 764) and is operable to flex as the shaft assembly (750) flexes at the articulation joint (760).

[0047] A pair of sensors (770, 772) is positioned along the flex circuit (758) in a region proximal to the articulation joint (760), while a magnet (774) is positioned on the flex circuit (758) (or elsewhere within the distal shaft segment (764)) in a region distal to the articulation joint (760). Thus, the magnet (774) moves with the distal shaft segment (764) as the distal shaft segment (764) pivots relative to the proximal shaft segments (752, 754, 756) at the articulation joint (760), while the sensors (770, 772) remain stationary during such pivoting. The sensors (770, 772) are configured to track the position of the magnet (774) and thereby determine the pivotal position of the distal shaft segment (764) relative to the proximal shaft segments (752, 754, 756). In other words, sensors (770, 772) and magnet (774) cooperate to enable determination of the joint flexion angle formed by shaft assembly (750). Thus, sensors (770, 772) may collectively function as a position sensor, such as position sensor (112) of instrument (100).

[0048] As described above, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to a conductive mechanical feature. Additionally, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of generating electrical potentials between adjacent components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. In the context of the instruments (700, 750), such risks may arise with respect to the sensors (720, 722, 724, 770, 772), the electrical components to which the sensors (720, 722, 724, 770, 772) are coupled, and / or other features within the shaft assembly of the instruments (700, 750). Other components of the instruments (700, 750) that may present the above-mentioned risks will be apparent to those skilled in the art in light of the teachings herein.

[0049] G. Drive Control Embodiments for Instrument Body and Shaft Assembly 12-14 illustrate one example of an instrument 800 that may be incorporated into a robotic surgical system, such as the robotic surgical systems 10, 150 described herein. In addition to the teachings below, the instrument 800 may be constructed and operative in accordance with at least part of the teachings of U.S. Pat. No. 9,125,662, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. The instrument 800 of this example includes a body 810, a shaft assembly 820, and an end effector 830. The body 810 includes a base 812 configured to mate with a complementary component of a robotic arm (e.g., one of the robotic arms 160, 170, 180). The shaft assembly 820 includes a rigid proximal portion 822, an articulating portion 824, and a distal portion 826. The end effector 830 is fixed to the distal portion 826. The articulation portion 824 is operable to laterally deflect the distal portion 826 and the end effector 830 away from and toward a central longitudinal axis defined by the proximal portion 822. The end effector 830 of this example includes a pair of jaws 832, 834. By way of example only, the end effector 830 may be configured and operable like any of the various end effectors 46, 56, 66, 102, 230, 320, 350, 620 described herein.

[0050] As shown in FIGS. 13 and 14 , multiple drive cables (850, 852) extend from the main body (810) to the joint portion (824) to drive the articulation of the joint portion (824). The cable (850) is wrapped around a drive pulley (862) and a tensioner (860). The cable (850) further extends around a pair of guides (870, 872) such that the cable (850) extends along the shaft assembly (820) in two segments (850 a, 850 b). The cable (852) is wrapped around a drive pulley (866) and a tensioner (864). The cable (852) further extends around a guide (880) such that the cable (852) extends along the shaft assembly (820) in two segments (852 a, 852 b). In this embodiment, each drive pulley (862, 866) is configured to couple with a corresponding drive member (e.g., a drive spindle, etc.) of the robotic arm component to which base (812) is fixed. Rotation of drive pulley (862) causes one segment (850a) of cable (850) to translate in a first longitudinal direction along shaft assembly (820), while the other segment (850b) simultaneously translates in a second (opposite) direction along shaft assembly (820). Similarly, rotation of drive pulley (866) causes one segment (852a) of cable (852) to translate in a first longitudinal direction along shaft assembly (820), while the other segment (852b) simultaneously translates in a second (opposite) direction along shaft assembly (820).

[0051] As shown in FIG. 14 , the articulation section (824) of this example includes a mid-shaft segment (880) longitudinally interposed between the proximal portion (822) and the distal portion (826). A ball-shaped feature (828) at the proximal end of the distal portion (826) is seated within a socket at the distal end of the mid-shaft segment (880) such that the distal portion (826) is operable to pivot relative to the mid-shaft segment (880) along one or more planes. Segments (850a, 850b) of the drive cable (850) terminate in corresponding ball-shaped ends (894, 890) secured to the ball-shaped feature (828) of the distal portion (822). Thus, the drive cable (850) is operable to drive pivotal movement of the distal portion (826) relative to the mid-shaft segment (880) based on the direction in which the drive pulley (862) rotates. A ball-shaped feature (882) on the proximal end of the intermediate portion (880) is seated in a socket on the distal end of the proximal portion (822) such that the intermediate portion (880) is operable to pivot relative to the proximal portion (822) along one or more planes. In some variations, this pivoting movement of the intermediate portion (880) relative to the proximal portion (822) is driven by a cable (852). As also shown in FIG. 14 , an electrical cable (802) passes through the articulation portion (824). The electrical cable (802) provides a path for electrical communication to the end effector (830), thereby enabling delivery of power (e.g., RF energy) to one or more electrodes within the end effector (830), providing a path for electrical signals from one or more sensors within the end effector (830) to be returned to the body (810), and / or providing other forms of electrical communication.

[0052] As discussed above, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of undesired crossing of power or signals from one electrical feature to another and / or from one electrical feature to a conductive mechanical feature. Additionally, the instruments (150, 200) may include electrical features and / or conductive mechanical features that may pose a risk of generating electrical potentials between adjacent components or creating capacitive coupling between electrical features and / or between electrical features and conductive mechanical features. In the context of the instrument (800), such risks may arise with respect to the drive cables (850, 852), electrical features within the shaft assembly (820), and / or components (850, 852) that are coupled to other features within the instrument (800). Other components of the instrument (800) that may present the above-mentioned risks will be apparent to those skilled in the art in light of the teachings herein.

[0053] H. Examples of Electrical Features at Interfaces Between Modular Components of an Appliance In some cases, it may be desirable to provide a surgical instrument that allows for modular coupling and decoupling of components. For example, FIG. 15 illustrates one embodiment of an instrument 900 that includes a handle assembly 910 and a modular shaft assembly 950. While the instrument 900 in this embodiment is handheld, similar features and modularity could easily be incorporated into a robotically controlled instrument. The handle assembly 910 in this embodiment includes a body 912, an activation button 914, a pivoting trigger 916, and a shaft interface assembly 920. The shaft interface assembly 920 includes a mechanical drive feature 922 and an array of electrical contacts 924. As will be apparent to those skilled in the art in view of the teachings herein, the electrical contacts 924 may be in electrical communication with control circuitry, a power source, and / or various other electrical features within the handle assembly 910.

[0054] The shaft assembly 950 includes a shaft portion 952 and an end effector 970 including a pair of jaws 972, 974. The shaft portion 952 and the end effector 970 may be configured and operable in accordance with any of the various shaft assemblies and end effectors described herein. The shaft assembly 950 of this example further includes a handle interface assembly 960. The handle interface assembly 960 includes a mechanical drive feature 962 and a plurality of electrical contacts (not shown). As will be apparent to those skilled in the art in view of the teachings herein, these electrical contacts of the handle interface assembly 960 may be in electrical communication with one or more electrodes, sensors, and / or other electrical components within the shaft portion 952 and / or the end effector 970.

[0055] When the shaft assembly (950) is coupled to the handle assembly (910), the mechanical drive feature (922) of the handle assembly (910) mechanically couples with the mechanical drive feature (962) of the shaft assembly (910), and the mechanical drive features (922, 962) may cooperate to transfer motion from a power source (e.g., pivoting trigger (916), motor, etc.) within the handle assembly (950) to one or more components within the shaft portion (952), and in some variations, to the end effector (970). In some variations, the mechanical drive features (922, 962) cooperate to transfer rotational motion from a power source (e.g., pivoting trigger (916), motor, etc.) within the handle assembly (910) to one or more components within the shaft portion (952), and in some variations, to the end effector (970). Additionally or alternatively, the mechanical drive features (922, 962) may cooperate to transmit linear translational motion from a power source (e.g., a pivoting trigger (916), a motor, etc.) within the handle assembly (910) to one or more components within the shaft portion (952) and, in some variations, the end effector (970).

[0056] When the shaft assembly (950) is mated with the handle assembly (910), the electrical contacts (924) of the shaft interface assembly (920) also mate with complementary electrical contacts of the handle interface assembly (960), and the contacts establish electrical continuity with each other, thereby enabling communication of power, signals, etc., between the handle assembly (910) and the shaft assembly (950). In addition to, or instead of, having the contacts (924), electrical continuity may be provided between the handle assembly (910) and the shaft assembly (950) via one or more electrical couplings in the mechanical drive features (922, 962). As will be apparent to those skilled in the art in view of the teachings herein, such electrical continuity may include a slip coupling and / or various other types of couplings.

[0057] In some scenarios where power or electrical signals are transmitted across mating contacts that provide electrical continuity between two components of an instrument (e.g., contacts 924 of the shaft interface assembly 920 and complementary electrical contacts of the handle interface assembly 960), there may be a risk of a short circuit forming between such contacts. This may be a particular risk when contacts that are supposed to be electrically isolated from one another are located in close proximity to one another and the area in which these contacts are located may be exposed to fluids during use of the instrument. Such fluids may create electrical bridges between the contacts and / or bleed signals being communicated between contacts that are supposed to be coupled to one another. Therefore, it may be desirable to provide features to prevent or otherwise address such occurrences at the contacts of an instrument such as instrument 900.

[0058] In some scenarios where power or electrical signals are transmitted across a mechanical coupling between different components of an instrument (e.g., via a slip coupling, etc.), such coupling may provide variable electrical resistance in the shaft assembly or other assembly of the instrument. For example, movement in the mechanical drive features (922, 962) may provide variable electrical resistance in the electrical slip coupling between the mechanical drive features (922, 962). This variable electrical resistance can affect the communication of power or electrical signals across the slip coupling. This, in turn, can result in signal loss or power reduction. Therefore, it may be desirable to provide features to prevent or otherwise address such occurrences in electrical couplings found in mechanical couplings between two moving parts of an instrument, such as instrument 900.

[0059] IV. Exemplary Features for Monopolar Surgical Instrument Energy Pathways The following description relates to examples of different features that may be incorporated into any of the various monopolar RF electrosurgical instruments (40, 420) described above. While these examples are provided separately from one another, features described in any of the following examples may be combined with features described in other examples described below. Accordingly, the features described below may be combined in various permutations, as will become apparent to those skilled in the art in light of the teachings herein. Similarly, various ways in which the features described below may be incorporated into any of the various instruments (40, 420) described above will become apparent to those skilled in the art in light of the teachings herein. It should be understood that the features described below may be incorporated into robotically controlled monopolar RF surgical instruments and / or handheld monopolar RF surgical instruments.

[0060] FIG. 16 illustrates an example of a monopolar RF energy delivery system (1000) that is a modified version of the RF energy delivery system (400) described above with reference to FIG. 16. The RF energy delivery system (1000) of this example includes a generator (1010), a delivery instrument (1020), a first grounding pad assembly (1040), and a second grounding pad assembly (1042). In addition to the teachings below, the instrument (1020) may be constructed and operable in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2019 / 0201077, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. The generator (1010) is operable to deliver monopolar RF energy to the instrument (1020) via a cable (1030) coupled to the generator (1010) via a port (1014). In some variations, the port (1014) includes an integrated sensor. By way of example only, a sensor within such port 1014 may be configured to monitor whether excess or inductive energy is radiating from the generator 1010. The instrument 1020 includes a body 1022, a shaft 1024, a sensor 1026, and a distal electrode 1028 configured to contact the patient P and thereby apply monopolar RF energy to the patient P. By way of example only, the sensor 1026 may be configured to monitor whether excess or inductive energy is radiating from the instrument 1020. Based on a signal from the sensor 1026, a control module within the generator 1010 may passively throttle the ground return from the grounding pad assembly 1040 based on data from the sensor 1026.

[0061] As shown, a dual grounding pad configuration may be utilized, including two or more resistively conductive grounding pad assemblies (1040, 1042) that provide direct contact between the patient's (P) skin and one or more metallic components of the grounding pad assemblies (1040, 1042). In some other variations, one or both of the grounding pad assemblies (1040, 1042) includes a capacitively coupled grounding pad that includes a gel material interposed between the patient (P) and a ground return plate. In this example, the grounding pad assemblies (1040, 1042) are positioned below the patient (P) and are coupled to the generator (1010) via cables (1032, 1036) via ports (1016, 1034, 1018, 1038), respectively. Any or all of the ports (1016, 1034, 1018, 1038) may include integrated sensors configured to monitor one or more therapeutic and / or diagnostic signals, as described below.

[0062] In some variations of the monopolar RF energy delivery system (1000), sensors in any or all of the ports (1016, 1034, 1018, 1038) may be configured to monitor whether excessive or inductive energy is radiating from one or both grounding pad assemblies (1040, 1042) during operation. This is because, for example, patient injury could occur during operation if one or both grounding pad assemblies (1040, 1042) are improperly positioned or secured to the patient (P) due to operator error. In this case, the therapeutic monopolar RF energy could be concentrated too much in one area on the patient's (P) skin, potentially resulting in injury to the patient (P), such as a severe burn. More specifically, the grounding pad assemblies (1040, 1042) provide a path of least resistance from the patient (P) back to the generator (1010), ensuring a region of low energy current density. If one or both of the return grounding pad assemblies (1040, 1042) do not make full contact with the patient's skin or are otherwise unable to safely dissipate the current, the spill current may have a density high enough to cause unintentional burns. Therefore, it is important to have good contact between the patient (P) and the grounding pad assemblies (1040, 1042). Otherwise, if the grounding pad assemblies (1040, 1042) are compromised in the quantity or quality of the pads or patient interface, the electrical circuit may be completed by several small ground contact points, such as ECG leads, towel clips, IV poles, or other surgical equipment, generating high current densities and potentially causing burns to the patient (P).

[0063] As described herein, a "therapeutic signal" is an RF energy signal applied to tissue via the electrodes (1028) to provide a desired therapeutic effect on the tissue. Examples of the desired therapeutic effect may include tissue sealing, electrocautery, ablation, or other tissue effects. Also, as described herein, a "diagnostic signal" is an RF energy signal transmitted to determine whether the grounding pad assemblies (1040, 1042) are properly coupled to the patient (P). Thus, the diagnostic signal is intended to diagnose the status of the monopolar RF energy delivery system (1000) and is not intended to produce an effect on tissue. In this example, the generator (1010) is configured to generate the therapeutic and diagnostic signals in accordance with the following teachings.

[0064] In some variations, the monopolar RF energy delivery system (1000) may be configured to generate and transmit a diagnostic signal through one or both grounding pad assemblies (1040, 1042) via cables (1032, 1036), respectively, to monitor placement errors of the grounding pad assemblies (1040, 1042). The RF energy delivery system (1000) may be further configured to terminate operation (e.g., by automatically causing the generator (1010) to disconnect power from or otherwise stop delivery of a therapeutic signal to the instrument (1020)) if the diagnostic signal returns outside a specified range. In this example, the generator (1010) is configured to output signals through three separate ports (1014, 1016, 1018). Specifically, the generator 1010 may output a therapeutic signal, such as a signal having a frequency in the range of approximately 300 kHz to 500 kHz, configured to affect tissue to the driven electrode 1028 of the instrument 1020 through the port 1014. The generator 1010 may also output a diagnostic signal, simultaneously with or separate from the therapeutic signal, through one of the ports 1016 or 1018 to one connected grounding pad assembly 1040 or 1042 electrically connected to the selected port 1016 or 1018, and receive the signal via a signal return path defined by the other port 1016 or 1018 and the connected grounding pad assembly 1040 or 1042. The diagnostic signal may be a lower frequency signal configured not to affect tissue. For example, the diagnostic signal may be transmitted in the range of approximately 15 kHz to approximately 50 kHz. In some embodiments, the diagnostic signal may be transmitted at or near 30 kHz. The generator 1010 may be configured to alternately generate and transmit diagnostic signals through each port 1016, 1018 and receive diagnostic signal returns through the other ports 1016, 1018. Thus, the return signals may be monitored for excessive energy losses or spikes outside of a predetermined signal range that may indicate a problem with the connection of one or both ground pad assemblies 1040, 1042 during operation.

[0065] In some surgical procedures, one or more components of the instrument 1020, such as components positioned within or coupled to the shaft 1024, may be constructed of metallic materials and, therefore, may generate significant undesirable capacitively coupled electrical potentials and currents along these components. As discussed above, such capacitive coupling may result in undesirable consequences such as power reduction, signal reduction, signal interference, patient injury, and / or other undesirable consequences. Therefore, it may be desirable to provide features to prevent or otherwise address capacitively coupled currents. In some variations, an instrument shield 1044 may be included on or within the instrument 1020 to collect capacitively coupled energy, thereby shielding the metallic components from undesired electrical currents and preventing them from flowing throughout the system 1000. The shield 1044 may be configured to couple to or wrap around a metal component to collect and return capacitively coupled current to the generator 1010 via a conductor 1046 that further couples to a return cable of the grounding pad assembly, such as the cable 1032 of the grounding pad assembly 1040. Instead of flowing through the metal component toward other grounded components of the system 1000, the capacitively coupled current flows through the shield 1044, the wire 1046, and the cable 1032 back to the generator 1010; therefore, undesired currents do not interfere with the therapy signal or result in injury to the patient P. This may also allow the generator 1010 to more effectively monitor its therapy signal output through the port 1014.

[0066] However, as mentioned above, some systems (1000) can be configured to closely monitor the energy flowing through the return path cables (1032, 1036) to the generator (1010) for excessive energy spikes or losses that may indicate a problem in the operation of the system (1000). By shunting capacitively coupled current from the instrument (1020) through at least one return cable (1032, 1036) of one grounding pad assembly (1040, 1042), the generator (1010) can detect a significant energy imbalance between the return cables (1032, 1036), and the generator (1010) can consequently disconnect power to the instrument (1020) (e.g., cease delivery of the treatment signal). For example, in the configuration shown in FIG. 16, approximately 75% of the total energy output from the generator (1010) can be returned through only one of the cables (1032, 1036). Therefore, it may be desirable to provide features that more evenly balance the ground return signals between the return cables (1032, 1036). Examples of such features are described in more detail below.

[0067] A. Exemplary monopolar surgical instrument energy path using a filter 17 illustrates the monopolar RF energy delivery system (1000) in one exemplary configuration for balancing the current returned to the generator (1010) between the return path cables (1032, 1036) of the ground pad assemblies (1040, 1042). Specifically, the wire (1046) is configured to be electrically coupled to a "T" junction (1048), which is further electrically coupled to the respective return path cables (1032, 1036) via a pair of leads (1052, 1054). In this example, because each cable (1032, 1036) provides a relatively similar resistance path from the shield (1044) through the "T" junction (1048) and back to the generator (1010), the energy shunted from the shield (1044) through the cables (1032, 1036) can be divided relatively evenly (i.e., in substantially equal portions) between the cables (1032, 1036). In some cases, the portion of the current shunted to cable (1032) can be up to about 30% of the portion of the current shunted to cable (1036). The generator (1010) can more effectively monitor the balanced combination of therapeutic (e.g., 300-500 kHz) and diagnostic (e.g., 30 kHz) return signals flowing through the cables (1032, 1036), thus avoiding misinterpretation of unbalanced signals that could indicate a problem within the system (1000) or with the positioning of either ground pad assembly (1040, 1042).

[0068] However, as described above, the generator 1010 may be configured to alternately generate and transmit lower frequency diagnostic signals through the grounding pad assemblies 1040, 1042 via the ports 1016, 1018. By including a "T" junction 1048, an electrical short is introduced between the cables 1032, 1036. To prevent a short from disabling the diagnostic signaling procedure, a signal filter 1050 may be electrically coupled onto either lead 1050, 1052, thereby prohibiting diagnostic signals from passing through the lead 1050, 1052 while allowing therapeutic signals to pass through the lead 1050, 1052. More specifically, the filter 1050 may be configured as a high-pass filter to block lower range signals from passing through the lead 1050, 1052 and to allow higher range signals to pass through the lead 1050, 1052. Thus, in a configuration in which the diagnostic signal is transmitted at or near 30 kHz, the filter (1050) may be configured as either an active or passive high-pass filter, for example, with a cutoff frequency at or near 45 kHz. However, it should be understood that while an example of a particular signal range and one particular cutoff frequency is described herein, various other signal ranges and cutoff frequencies may be configured as desired.

[0069] B. Energy Path of an Exemplary Monopolar Surgical Instrument Using a Transformer 18 illustrates the monopolar RF energy delivery system (1000) in another exemplary configuration for balancing the current returned to the generator (1010) between the return path cables (1032, 1036) of the ground pad assemblies (1040, 1042). In particular, the wire (1046) is configured to be electrically coupled to a transformer (1060), such as a primary winding of the transformer (1060), the dual secondary windings of which are further electrically coupled to the respective return path cables (1032, 1036) via a pair of leads (1062, 1064). In this manner, energy shunted from the shield 1044 through the cables 1032, 1036 may be divided relatively evenly between the cables 1032, 1036, because each cable 1032, 1036 provides a relatively similar resistance path from the shield 1044 through the transformer 1060 and back to the generator 1010. The transformer 1060 may be, for example, a current load balancing transformer.

[0070] While various alternative systems and methods for balancing the energy of wire (1046) to cable (1032, 1036) are described herein, it should be understood that various alternative configurations are also contemplated, as would be known and understood by those skilled in the art in light of the teachings herein.

[0071] V. EMBODIMENTS OF AN ELECTROSURGICAL INSTRUMENT SYSTEM WITH A PARASITIC ENERGY LOSS MONITOR The following description relates to examples of different features that may be incorporated into any of the various RF electrosurgical instruments (40, 50, 420) described above. While these examples are provided separately from one another, features described in any of the following examples may be combined with features described in other examples described herein. Accordingly, the features described below may be combined in various permutations, as will become apparent to those skilled in the art in light of the teachings herein. Similarly, various ways in which the features described below may be incorporated into any of the various instruments (40, 50, 420) described above will become apparent to those skilled in the art in light of the teachings herein. It should be understood that the features described below may be incorporated into robotically controlled and / or handheld surgical instruments, including, but not limited to, instruments powered via an on-board battery and / or via a wire to an external power source. This includes, but is not limited to, the various types of robotically controlled instruments described above, the various types of handheld instruments described above, the various types of battery-powered instruments described above, and the various types of instruments powered via a wire to an external power source.

[0072] As mentioned above, several aspects of the present disclosure are presented for surgical instruments with improved device capabilities to reduce undesirable operation side effects. Examples of such devices and related concepts are disclosed in U.S. Patent Application Publication No. 2019 / 0201077, published July 4, 2019, entitled "Interruption of Energy Due to Inadvertent Capacitive Coupling," the disclosure of which is incorporated herein by reference in its entirety. Specifically, surgical instruments may include means for limiting capacitive coupling to improve monopolar RF isolation for use independently or in concert with another advanced energy modality. Capacitive coupling generally occurs when there is a transfer of energy between nodes induced by an electric field. Capacitive coupling can occur when two or more electrosurgical instruments are used in or around a patient during surgery. Capacitive coupling can also occur within a single instrument or a single instrument system. For example, capacitive coupling can occur between conductive components in close proximity to one another within the same instrument, including components such as those described above with reference to FIGS. 1-15. In some cases, capacitive coupling may be desirable because it allows additional devices to be inductively powered, but accidental capacitive coupling during surgery or around the patient in general can have very detrimental effects.

[0073] Parasitic or accidental capacitive coupling can occur in unknown or unpredictable locations, causing energy to be applied to unintended areas. When a patient is under anesthesia and unable to provide any response, parasitic capacitive coupling can cause unwanted thermal damage to the patient before the operator realizes that any thermal damage is occurring. Additionally or alternatively, parasitic capacitive coupling can result in unwanted power loss. Such unwanted power loss due to parasitic capacitive coupling can result in undesirably low delivery of electrical energy (e.g., monopolar RF energy) to tissue within the patient, resulting in undesirable surgical outcomes. Additionally or alternatively, unwanted power loss due to parasitic capacitive coupling can result in corrupted feedback signals from sensors or other electrical components, and such corrupted electrical signals can result in unreliable feedback data. Therefore, it is desirable to prevent or at least limit parasitic or accidental capacitive coupling in surgical instruments, typically during surgery.

[0074] In some variations of the instruments described above, the electrosurgical system includes a surgical instrument and a console, such as console (20) (see FIG. 1). The console may include one or more generators, as well as a data processor, memory, and other computing equipment. Each generator may be configured to modulate the transmission of energy from the generator to the particular surgical instrument it is powering if capacitive coupling is detected along any of the components coupled to that surgical instrument. One or more safety fuses, sensors, controls, and / or algorithms may be in place to automatically trigger modulation of the energy delivered by the generator in these scenarios. Alerts, including audio signals, vibrations, and visual messages, may be issued to notify the surgical team that energy has been or is being modulated due to the detection of capacitive coupling.

[0075] In some embodiments, the system includes a means for detecting that a capacitive coupling event has occurred. For example, an algorithm including input from one or more sensors monitoring events around the system can apply situational awareness and other programmatic means to conclude that capacitive coupling is occurring somewhere within the system and react accordingly. A system with situational awareness means that the system can be configured to predict possible scenarios based on current environmental and system data and determine that the current situation follows a pattern that results in a predictable next step. As an example, the system can apply situational awareness to the context of processing a capacitive coupling event by recalling examples of similar surgical situations in which various sensor data is detected. The sensor data may indicate an increase in current at two specific locations along the closed-loop electrosurgical system, which, based on previous data from similar surgical situations, indicates a high probability that a capacitive coupling event is imminent.

[0076] In some aspects, surgical instruments may be modified with structures to limit the occurrence of capacitive coupling or reduce collateral damage otherwise caused by capacitive coupling. For example, additional insulation strategically placed within or around the surgical instrument may help limit the occurrence of capacitive coupling. In other cases, the end effector of the surgical instrument may include modified structures that reduce the occurrence of current displacement, such as rounding the tip of the end effector or particularly shaping the blade of the end effector to behave more like a monopolar blade while still operating as a bipolar device.

[0077] In some aspects, the system may include passive means for mitigating or limiting the effects of capacitive coupling. For example, the system may include leads that can shunt energy to a neutral node through conductive passive components. In general, any and all of these aspects may be combined or included within a single system to address the challenges posed by multiple electrical components susceptible to capacitive coupling during patient surgery.

[0078] In scenarios where there are multiple power sources near the patient (P) and / or multiple conductive components within the instrument in close proximity to power-carrying components within the same instrument, parasitic capacitive coupling can pose a risk during surgery. Because the patient (P) cannot be expected to exhibit any reaction during surgery, if unknown or unexpected capacitive coupling occurs, the patient (P) may end up suffering burns in unintended locations. Generally, energy anomalies such as capacitive coupling should be minimized or otherwise corrected to improve patient safety and / or otherwise provide desirable surgical outcomes. To monitor for the occurrence of capacitive coupling or other types of energy anomalies, multiple smart sensors can be integrated into the electrosurgical system as indicators to determine whether excess or inductive energy is being radiated externally from one or more power sources. An example of a system (1100) incorporating such smart sensors is shown in FIG. 19. The system (1100) of FIG. 19 is substantially similar to the system (400) of FIG. 7 described above, but with the modifications described below.

[0079] The system 1100 of FIG. 19 is operable to detect incidental capacitive coupling within or between components of the system 1100 in accordance with at least one aspect of the present disclosure. The system 1100 of this example includes a generator 1110, a delivery instrument 1120, and a grounding pad assembly 1140. The instrument 1120 of the system 1100 may include means for applying RF or ultrasonic energy to a distal electrode 1128 and, in some cases, may include a blade and / or a pair of jaws for grasping or clamping tissue. In addition to the teachings below, the instrument 1120 may be constructed and operable in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2019 / 0201077, the disclosures of which are incorporated herein by reference in their entirety, and / or various other references cited herein.

[0080] The generator 1110 may be operable to deliver monopolar RF energy to the instrument 1120 via a cable 1130 coupled to the generator 1110 via a port 1114. Energy powered by the generator 1110 may be exposed to the patient P through a distal electrode 1128 of the instrument 1120. In this embodiment, the port 1114 includes an integrated sensor 1142 and tuner 1148. By way of example only, the sensor 1142 in the port 1114 may be configured to monitor whether excess or inductive energy is radiating from the generator 1110 and / or whether parasitic losses are occurring in the energy being delivered by the generator 1110. The tuner 1148 may be configured to modulate the delivery of energy by the generator 1110 via the port 1114 based at least in part on feedback from the sensor 1142. An example of how such modulation can be performed is described in more detail below.

[0081] The instrument 1120 includes a body 1122, a shaft 1124, a sensor 1126, and a distal electrode 1128 configured to contact the patient (P) and thereby apply monopolar RF energy to the patient (P). By way of example only, the sensor 1126 may be configured to monitor whether excess or inductive energy is radiating from the instrument 1120 and / or whether parasitic losses are occurring in the signal from the instrument 1120. Based on a feedback signal from the sensor 1126, a control module within the generator 1110 may passively throttle or otherwise adjust the ground return from the grounding pad assembly 1140. Additionally or alternatively, the ground return from the grounding pad assembly 1140 may be throttled or otherwise adjusted based at least in part on feedback from the sensor 1142 and / or other sources.

[0082] The grounding pad assembly (1140) is configured to provide an electrical ground to the patient (P) when the surgical instrument (1120) contacts the patient (P) and applies electrosurgical energy to the patient (P). In this role, the grounding pad assembly (1140) may further shunt excess energy (e.g., unwanted excess electrosurgical energy) that is undesirably delivered to the patient (P). In some variations, the grounding pad assembly (1140) includes one or more resistively conductive grounding pads that provide direct contact between the patient's (P) skin and one or more metal components of the grounding pad. In some other variations, the grounding pad assembly (1140) includes a capacitively coupled grounding pad that includes a gel material interposed between the patient (P) and a ground return plate. By way of example only, the grounding pad assembly (1140) may be configured and operative similarly to a Smart MEGADYNE™ MEGA SOFT™ pad by Ethicon US, LLC. In this embodiment, the grounding pad assembly 1140 is positioned under the patient (P) and is coupled to the indifferent electrode 1112 of the generator 1110 via a cable 1132. The cable 1132 is coupled via ports 1116, 1134. Either or both of the ports 1116, 1134 may include integrated sensors 1144, 1146. By way of example only, such sensors 1144, 1146 on either or both of the ports 1116, 1134 may be configured to monitor whether excess or inductive energy is radiating from the grounding pad assembly 1140. Based on feedback signals from one or both of the sensors 1144, 1146, a control module within the generator 1110 may passively throttle or otherwise adjust the ground return from the grounding pad assembly 1140.

[0083] As shown in FIG. 16 , the sensors (1126, 1142, 1144, 1146) of this example are positioned where energy can radiate inductively. One or more of the sensors (1126, 1142, 1144, 1146) may be configured to detect capacitance, and when placed in strategic locations within the system (1100), a capacitance reading may mean that a capacitive leak is occurring near the sensor (1126, 1142, 1144, 1146). With the knowledge that other sensors near or throughout the system do not display a capacitance reading, it can be concluded that a capacitive leak is occurring in close proximity to the sensor (1126, 1142, 1144, 1146) providing a positive reading. Other sensors, such as capacitive leak monitors or detectors, may also be used. These sensors may be configured to provide a warning, such as lighting up, emitting a noise, or sending a signal to an eventual display monitor. Additionally, generator (1110) may be configured to automatically modulate the energy delivered through port (1114) to stop further capacitive coupling from occurring.

[0084] In some embodiments, the generator 1110 may be configured with situational awareness that can help predict when capacitive coupling may occur during surgery. The generator 1110 can utilize a capacitive coupling algorithm to monitor the generation of energy flowing through the system 1100 and, based on previous data regarding the energy state within the system for treating similar situations, can conclude that capacitive coupling may occur if no further action is taken. For example, during a surgery involving a prescribed method for how to operate the instruments 1120 and how much power should be used during a particular step of the surgery, the generator 1110 can draw from previous similar surgeries to note that capacitive coupling is more likely to occur after that particular step of the surgery. During monitoring of the surgical step, if the same or very similar energy profile occurs during or immediately before a step that is expected to tend to induce capacitive coupling, the generator 1110 can issue a warning indicating that capacitive coupling may occur. The operator may be given the option to reduce the peak voltage at the surgical instrument 1120, interrupt power generation by the generator 1110, or otherwise modulate the delivery of power from the generator 1110 to the instrument 1120, thereby eliminating the possibility of capacitive coupling before it can occur, or at least limiting any unintended effects caused by the momentary onset of capacitive coupling.

[0085] In some embodiments, the surgical instrument 1120 may include structural measures to reduce or prevent capacitive coupling. For example, insulation within the shaft 1124 of the surgical instrument 1120 may reduce the generation of inductance. In other cases, the wires 1130 connecting the generator 1110 to components on or within the instrument 1120 or body 1122 may be shielded and coupled to a ground source by returning through the cable 1130 or by coupling to a return path cable 1132 (not shown). In addition to sensing power output to the electrodes 1128, the sensor 1142 may be further configured to sense current returning through the cable 1130 to the generator 1110 or other ground source. As another example, insulating plastic elements may be intermittently present within the shaft 1124 to prevent capacitive coupling from traveling long distances within the shaft. Other insulator-type elements may be used to achieve a similar effect.

[0086] As mentioned above, some existing instruments may be configured to interrupt power generation by the generator upon detecting capacitive coupling at one or more sensors. While such power interruption may be effective in preventing undesirable results that might otherwise result from inadvertent capacitive coupling, such power interruption may not be appreciated by the operator of the instrument (1120), especially if the power interruption occurs suddenly in the middle of a surgical procedure. A power outage during a surgical procedure can irritate the operator and increase the duration of the procedure. Therefore, it may be more desirable to modulate the power delivered from the generator (1110) to the instrument (1120) without interrupting power to prevent undesirable results that might otherwise result from inadvertent capacitive coupling. Such power modulation may be provided on an ad hoc basis in response to real-time feedback from sensors, as described herein. While exemplary methods are described below with continued reference to the system (1100), it should be understood that the methods described herein may be incorporated into other electrosurgical systems that may include sensors for monitoring capacitive leakage, including systems that offer modes of power delivery not necessarily limited to monopolar RF power delivery.

[0087] Figure 20 shows a flow diagram of an exemplary method for monitoring energy loss in a surgical instrument operable to apply RF energy to tissue, such as any one of the instruments (40, 50, 420, 1120) described herein. By using the exemplary method, such as in the system (1100), one or more of the sensors (1126, 1142, 1144, 1146) (see Figure 19) are configured to monitor capacitively coupled current and instrument impedance and provide feedback to the generator (1110) (or alternatively, to a data processor of the console (20) controlling the generator (1110). The generator (1110), or, for example, a local or cloud-based processing device coupled to the generator (1110), can then determine whether the generator (1110) should increase or decrease the voltage delivered to the electrode (1128) of the instrument (1120). If the capacitively coupled current is equal to or greater than a predetermined threshold current, the generator 1110 may be instructed to reduce voltage, thereby reducing capacitive redirection to a level below the damage threshold but still allowing the instrument 1120 and operator to operate. Otherwise, if the capacitively coupled energy is below the predetermined threshold, the generator 1110 may be instructed to increase voltage to provide more power to the instrument 1120 while still monitoring the capacitive coupling threshold. In this manner, by monitoring the level of capacitive coupling (e.g., too much leakage) rather than simply the presence or absence of capacitive coupling, the system 1100 can track anomalous energy redirection as the generator 1110 adjusts voltage from a potentially high-voltage power use (e.g., 7,000 volts) to a significantly lower voltage (e.g., 1,000 volts) while simultaneously maintaining the same power level by adjusting the output current. As these adjustments are made, the generator (1110), sensors (1126, 1142, 1144, 1146) or other monitoring devices monitor for abnormal capacitively coupled currents to ensure that the capacitively coupled currents move below tissue damage threshold levels, at which point adjustments are made to allow the instrument (1120) to continue being used in surgery.In other words, capacitive coupling can be adequately addressed without having to stop the surgical procedure due to a sudden interruption of power from the generator 1110. However, in some cases, ad-hoc power modulation may not be sufficient to address capacitive coupling, and it may ultimately be desirable to interrupt power from the generator 1110 as a last resort.

[0088] When output energy from the instrument (1120) is capacitively coupled to the patient's (P) tissue, a lower impedance load may be seen by the generator (1110) compared to the impedance load presented by the tissue alone without capacitive coupling. Monitoring for sudden changes in impedance could signal harmful arcing or breakdown. Therefore, the generator (1110) may be monitored for arcing, and that data may be used in conjunction with local electronics within the instrument (1120) to better assess what percentage of output power is being delivered to the electrodes (1128) relative to the capacitive coupling. This may allow the monitoring system to actively provide feedback for adjusting the generator (1110) output in real time during operation, thereby allowing the generator (1110) to adjust voltage or other electrical parameter(s) as needed. In some variations, a shield (1129) is included in the instrument (1120) to collect the capacitively coupled current, which it provides to the sensors (1126, 1142, 1144, 1146) for measurement and monitoring. The system 1100 may include a controller 1108 (e.g., a hub or data center) having processing means for coupling to the generator 1110, or the processing means may be included within the generator 1110. Thus, electrosurgical parameters may be measured by the sensors 1126, 1142, 1144, 1146 and compared by the processor to estimates of what normal energy application or normal tissue impedance would be for the operating conditions. If any parameter is outside of a predetermined range, the generator 1110 may recognize a possible capacitive coupling or breakdown of the insulation system on the instrument.

[0089] Alternatively, the tuner 1148 may be coupled to the output port 1114 to automatically adjust capacitive and / or inductive loads, thereby adjusting for higher or lower capacitance components of the instrument 1120, such as a metal shield 1129 in, on, or around at least a portion of the instrument 1120. The components may be measured upon connection of the instrument 1120, and then adjustments may be made to compensate. Additionally or alternatively, if a very high voltage is sensed by one or more of the sensors 1126, 1142, 1144, 1146, the system 1100 may add or subtract some capacitance and / or inductance to reduce the energy output at the port 1114.

[0090] 20 , one embodiment of the method 1150 described above begins with one or more sensors 1126, 1142, 1144, 1146 determining (block 1152) a maximum threshold or range of acceptable energy loss and / or a maximum threshold or range of acceptable impedance change during operation. These thresholds or ranges may be determined by the system 1100, such as the controller 1108 or generator 1110, based on known parameters of the surgical procedure at hand, based on known parameters of the instrument 1120, based on previous surgical data collected from similar surgical procedures or with similar instruments, and / or based on other factors. In some variations, the tuner 1142 automatically executes a calibration algorithm to detect load parameters of the coupled instrument 1120 when the instrument 1120 is coupled to the generator 1110, thereby appropriately determining a maximum threshold or range of energy loss and / or a maximum threshold or range of impedance change that is acceptable during operation based on the detected load parameters of the coupled instrument 1120. Such ad hoc determination may further allow power delivery adjustments to be made, even before power is initially delivered, to compensate for the detected load parameters of the coupled instrument 1120. By way of example only, such initial ad hoc power delivery adjustments may include adding or subtracting capacitance and / or inductance to the power delivered to the coupled instrument 1120, thereby minimizing the risk of capacitive coupling occurring during use of the coupled instrument 1120 during a surgical procedure. Regardless of whether an initial ad hoc power delivery adjustment is made based on detected characteristics of the coupled instrument (1120), the determined maximum energy loss threshold or range (block 1152) and the determined maximum impedance change threshold or range (block 1152) can each be configured to cause the system (1100) to instruct the generator (1110) to adjust the power output of the generator (1110) as necessary to ensure that the instrument (1120) operates effectively and injury to the patient (P) is avoided.

[0091] Once the threshold or range has been determined, in the next step (block 1154), the operator activates the end effector (e.g., electrode 1128) of the instrument 1120 to begin operation on the patient P. As described above, in a subsequent step (block 1156), one or more of the sensors 1126, 1142, 1144, 1146 monitor capacitively coupled currents induced along components of the instrument 1120 and / or wire 1130. Impedance may also be monitored during this same step (block 1156).

[0092] Based on data from the one or more sensors (1126, 1142, 1144, 1146), the method (1150) further includes determining (block 1166) via the controller (1108) or generator (1110) whether the capacitively coupled current meets or exceeds a previously determined threshold or range (block 1152). If the capacitively coupled current does not meet or exceed the previously determined threshold or range (block 1152), the method (1150) further includes determining (block 1168) via the controller or generator (1110) whether an impedance change meets or exceeds the previously determined threshold or range (block 1152), such an impedance change being indicative of undesired capacitive coupling. For example, a sudden and substantial drop in impedance may be indicative of undesired arcing between the electrode (1128) and tissue, which may be a result of undesired capacitive coupling. If neither the capacitive coupling current nor the impedance change meets or exceeds the corresponding previously determined threshold or range (block 1152), the system (1100) continues to activate the end effector (block 1154) and monitor the capacitive coupling current and / or impedance (block 1156).

[0093] If a determination (block 1166) reveals that the capacitive coupling current meets or exceeds a previously determined threshold or range (block 1152), the method (1150) proceeds to a step (block 1160) in which one or more output parameters of the generator (1110) (e.g., voltage swing, current limit, power limit, etc.) are adjusted to prevent or otherwise address the occurrence of capacitive coupling. Similarly, if a determination (block 1168) reveals that the impedance change meets or exceeds a previously determined threshold or range (block 1152), the method (1150) proceeds to a step (block 1160) in which one or more output parameters of the generator (1110) (e.g., voltage swing, current limit, power limit, etc.) are adjusted to prevent or otherwise address the occurrence of capacitive coupling. Such adjustments may be performed via the tuner (1148), as described above. In some scenarios, such adjustments include reducing the output voltage of the generator (1110) while still maintaining substantially the same power level (despite the reduced voltage).

[0094] After adjusting the output parameters of the generator 1110 (block 1160), the system 1100 may determine whether these adjusted output parameters exceed appropriate limits (block 1162). If the adjusted output parameters do not exceed appropriate limits, the system 1100 may continue activating the end effector (block 1154) and monitoring the capacitive coupling current and / or impedance (block 1156). Thus, the operator can continue the surgical procedure without interruption, and the system 1100 provides ad hoc adjustments to power delivery from the generator 1110 based on real-time feedback from one or more sensors 1126, 1142, 1144, 1146 to prevent undesirable results that might otherwise occur due to capacitive coupling during operation of the instrument 1120.

[0095] If the system 1100 determines that the adjusted output parameter exceeds an appropriate limit (block 1162), this may mean that the system 1100 is unable to make appropriate adjustments to the energy delivered by the generator 1110 to the instrument 1120 to avoid undesirable results from capacitive coupling. In such a scenario, as a last resort, the method 1150 may provide for deactivation of the end effector of the instrument 1120 (block 1164). Such deactivation may be provided by stopping or otherwise interrupting energy delivery from the generator 1110 to the instrument 1120. In some variations, this deactivation (block 1164) may be provided for a predetermined duration (e.g., 1 second, 5 seconds, 1 minute, 5 minutes, etc.). After expiration of this predetermined duration, the method may again initiate activation of the end effector 1154, allowing the surgical procedure to once again continue according to the method 1150. If a deactivation (block 1164) is necessary, the system 1100 may also provide some type of alert to the operator to indicate that such deactivation (block 1164) is intentional, thereby avoiding confusion from the operator mistakenly thinking that the system 1100 has failed or that some other power failure has occurred. Such alerts may take the form of visual alerts, audible alerts, tactile alerts, and / or combinations of such forms.

[0096] VI. Example of an Energized Surgical Tool System with Multi-Generator Output Monitoring The following description relates to examples of different features that may be incorporated into any of the various surgical systems described above. Accordingly, the features described below may be combined in various permutations, as will become apparent to those skilled in the art in light of the teachings herein. Similarly, various ways in which the features described below may be incorporated into any of the various surgical systems described above will become apparent to those skilled in the art in light of the teachings herein. It should be understood that the features described below may be incorporated into robotically controlled surgical instruments and / or handheld surgical instruments.

[0097] As described above, some aspects of the present disclosure provide for surgical instruments with improved device capabilities to reduce undesirable operation side effects. In particular, as described with respect to FIG. 1 , some surgical instruments or systems may be configured to apply two or more different types of energy modalities. For example, this may include instruments configured to apply two or more of monopolar RF, bipolar RF, or ultrasonic energy to tissue. The application of two or more energy modalities may require, in some cases, two or more generators, or in other variations, two or more generator outputs associated with the same generator. However, when two or more energy modalities are used simultaneously, the power outputs may induce crosstalk between the generator outputs, thereby causing undesirable effects as either instrument contacts the patient's tissue. Crosstalk may include signal amplification, reduction, interference, or other interactions between the two outputs. Therefore, it may be desirable to actively monitor one generator output using a monitoring array or generator to provide a set of energy output parameters to the second generator. Doing so may enable the second generator to output an energy signal that does not induce crosstalk between the two or more generator outputs.

[0098] 21 illustrates one exemplary dual energy delivery system 1200 including a generator 1210, a first delivery device 1220, a second delivery device 1221, a first grounding pad assembly 1240, and a second grounding pad assembly 1242. In addition to the teachings below, devices 1220 and 1221 may be constructed and operable in accordance with at least a portion of the teachings of U.S. Patent Application Publication No. 2019 / 0201077, the disclosure of which is incorporated herein by reference in its entirety, and / or various other references cited herein. The generator (1210) may include a first generator module (1250) and a second generator module (1252), each operable to deliver a different energy modality to the instruments (1220, 1221) via cables (1230, 1231) via power modules (1254, 1256), respectively.

[0099] The first instrument (1220) may be, for example, a bipolar RF instrument. The first instrument (1220) includes a body (1222), a sensor (1226), and an end effector (1224) having a distal electrode assembly (1228) configured to contact a patient (P) and thereby apply bipolar RF energy to the patient (P). In some variations, the electrode assembly (1228) has two electrodes positioned to simultaneously contact tissue and thereby deliver bipolar RF energy to the tissue. In some variations, the electrode assembly (1228) has three or more electrodes. By way of example only, the sensor (1226) may be configured to monitor whether excess energy or inductive energy is being emitted from the instrument (1220).

[0100] The second instrument (1221) may be, for example, a monopolar RF instrument. The second instrument (1221) also includes a body (1223), a sensor (1225), and an end effector (1227) having a distal electrode (1229) configured to contact the patient (P) and cooperate with one or more grounding pad assemblies (1240, 1242) to apply RF energy to the patient (P). By way of example only, the sensor (1225) may be configured to monitor whether excess or inductive energy is being emitted from the instrument (1220). Based on a signal from the sensor (1225), a control module within the generator (1210) may passively throttle the ground return from the grounding pad assemblies (1240, 1242) based on data from the sensor (1225). Although a bipolar instrument (1220) and a monopolar RF instrument (1221) are described, it should be understood that any two or more instruments having any two or more energy modalities, such as monopolar RF, bipolar RF, ultrasound, or any combination thereof, may alternatively be utilized.

[0101] As shown, a dual grounding pad configuration may be utilized in monopolar RF embodiments, including two or more resistively conductive grounding pads (1240, 1242) that provide direct contact between the patient's (P) skin and one or more metal components of the grounding pad. In some other variations, the grounding pad assemblies (1240, 1242) include capacitively coupled grounding pads that include a gel material interposed between the patient (P) and a ground return plate. In this example, the grounding pad assemblies (1240, 1242) are positioned below the patient (P) and are coupled to the generator (1210) via cables (1232, 1236), respectively.

[0102] In some variations of the energy delivery system 1200, one or both generator modules 1250, 1252 may include a power monitor, such as a sensor module 1260. The sensor module 1260 of one generator module 1250 may include a data processor configured to monitor the energy present at various points within the energy delivery system 1200 associated with the other generator module 1252, particularly the instrument 1221 belonging to the output module 1256. Thus, various measurement points indicative of the energy being output to the patient (P) by the second generator module 1252 may be monitored by the first generator module 1250 so that the first generator module 1250 can adjust its output parameters to avoid crosstalk.

[0103] The sensors (1234, 1235, 1237, 1238) may include, for example, RF power sensors, ammeters, voltmeters, ultrasonic transducers, or other similar power sensing devices and may be configured to monitor energy flowing through or radiating from various points powered by the power module (1256) and return energy measurements to the sensor module (1260) via a communication cable (1239). In particular, a first sensor (1234) may be positioned on the instrument (1221) and may be configured to measure capacitively coupled energy, a second sensor (1235) may be positioned on the return cable (1232) from the first grounding pad assembly (1240) to monitor energy returning from the patient (P) to the generator module (1252), a third sensor (1237) may be positioned on the return cable (1236) from the second grounding pad assembly (1242) to monitor energy returning from the patient (P) to the generator module (1252), and a fourth sensor (1238) may be positioned on the cable (1231) to monitor energy being output from the power module (1256) to the instrument (1221). Although four exemplary sensors (1234, 1235, 1237, 1238) are described in four separate locations for monitoring energy flowing through or radiating from various points powered by power module (1256), it should be understood that various other sensor locations are contemplated and that only one or a subset of sensors (1234, 1235, 1237, 1238) may be included in other variations of system (1200).

[0104] As will be described, during operation, the sensor module (1260) may monitor signals from any one or more of the sensors (1234, 1235, 1237, 1238) to determine parameters of the second output module (1256) to the second instrument (1221) and communicate the parameters to the first output module (1254) over the data connection (1262). The first output module (1254) is then configured to adjust its own output energy parameters to the first instrument (1220) to avoid outputting a signal that is too similar to the signal that the second output module (1256) is outputting to the second instrument (1221). The sensors (1234, 1235, 1237, 1238) may be configured to monitor any energy parameter, such as current, voltage, frequency, power level, and / or waveform, and the first output module (1254) may then be configured to adjust those same energy parameters. These adjustments may be made to avoid amplification, cancellation, interference, and / or other interactions between the outputs of the output modules (1254, 1256). In other words, the second output module (1256) may make ad hoc adjustments in real time to automatically adjust the frequency, waveform, and / or other parameters of its own output, thereby avoiding amplification, cancellation, interference, and / or other interactions with the sensed output of the first output module (1254). For example, if the sensor module (1260) determines that the second output module (1256) is outputting a 400 kHz unipolar RF signal, the first output module (1254) may adjust its own bipolar RF output signal to 800 kHz or 1 MHz to properly distinguish the signals. In some variations, a frequency multiplier circuit (e.g., a two-diode odd-order frequency multiplier, etc.) may be utilized with a single generator output module.

[0105] Some generator systems may respond poorly to excess capacitance in the load. In some cases, this can lead to the generator's tuned circuit output generating higher than expected voltages. These higher voltages may exceed the ratings provided by the generator manufacturer. This overvoltage situation can cause instruments powered by the generator to operate in an out-of-bounds region where the instrument insulation system is not rated for this higher voltage, leading to a potentially dangerous situation where the insulation breaks down and an electrical arc forms. Electrical arcs can be highly undesirable in surgery because they are unpredictable and can suddenly burn surrounding materials, thereby releasing chemicals and components not intended to be present in the surgical field. Burning insulation can further expose conductive surfaces not intended for patient contact. Therefore, to prevent or otherwise mitigate these problems, the energy delivery system (1200) may be further configured to perform energy parameter adjustments with respect to a time constant, which is based on the natural frequency of the electrical system. Specifically, the time constant is equal to the product of the circuit resistance (ohms) and the circuit capacitance (farads).

[0106] To perform the energy parameter adjustment with respect to the time constant, one or more of the sensors (1234, 1235, 1237, 1238) may monitor capacitive and resistive loads. The capacitive load may be monitored, for example, by the sensor (1234) measuring parasitic capacitive coupling induced in the instrument (1221). The resistive load may be monitored by a combination of the sensors (1234, 1235, 1237, 1238) measuring tissue load, such as may be defined by muscle-to-fat ratio. It should be understood that the above-described measurements and time constant adjustments may, in some variations, be performed by the energy delivery system (1200) without cooperation with any of the generator modules (1250, 1252).

[0107] Figure 22 illustrates an alternative configuration 1300 of the energy delivery system 1200. The components of the energy delivery system 1300 and their functions are the same as those described for the energy delivery system 1200, except as described below. Specifically, the energy delivery system 1300 includes a generator 1310, a first delivery device 1320, a second delivery device 1321, a first grounding pad assembly 1340, and a second grounding pad assembly 1342. The generator 1310 may include a first generator module 1350 and a second generator module 1352, each operable to deliver a different energy modality to the devices 1320 and 1321 via cables 1330 and 1331 via power modules 1354 and 1356, respectively. Additionally, while a bipolar instrument (1320) and a monopolar RF instrument (1321) are described, it should be understood that any two or more instruments having any two or more energy modalities, such as monopolar RF, bipolar RF, ultrasound, or any combination thereof, may be utilized instead.

[0108] In this variation, the generator module (1352) includes a power monitor, such as a sensor module (1360), coupled to the power module (1356). The sensor module (1360) of the second generator module (1352) may include a data processor configured to monitor energy present at various points within the energy delivery system (1300) associated with the other generator modules (1350), particularly the instrument (1320) belonging to the output module (1354). Thus, various measurement points indicative of the energy being output by the first generator module (1350) to the patient (P) may be monitored by the second generator module (1352) so that the second generator module (1352) can adjust its output parameters to avoid crosstalk. The sensors (1334, 1335) may include, for example, RF power sensors, ammeters, voltmeters, ultrasonic transducers, or other similar power-sensing devices and may be configured to monitor energy flowing through or radiating from various points powered by the power module (1354) and return energy measurements to the sensor module (1360) via the communication cable (1339). In particular, the first sensor (1334) may be positioned at the output of the power module (1354) and configured to measure the output energy signal provided to the powered appliance (1320), while the second sensor (1335) may be positioned on the appliance (1320) and configured to measure capacitively coupled energy. Although two exemplary sensors (1334, 1335) are described in two separate locations for monitoring energy flowing through or radiating from various points powered by power module (1354), it should be understood that various other sensor locations are contemplated and may include only one or a subset of sensors (1334, 1335).

[0109] As will be described, during operation, the sensor module (1360) may monitor any one of the sensors (1334, 1335) to determine parameters of the first output module (1354) to the first instrument (1320) and communicate the parameters to the second output module (1356) over the data connection (1362). The second output module (1356) is then configured to adjust its own output energy parameters to the second instrument (1321) to avoid outputting a signal too similar to the signal the first output module (1354) is outputting to the first instrument (1320). The sensors (1334, 1335) may be configured to monitor any energy parameter, such as current, voltage, frequency, power level, and / or waveform, and the second output module (1354) may then be configured to adjust those same energy parameters. These adjustments may be made to avoid amplification, cancellation, interference, and / or other interactions between the outputs of the output modules (1354, 1356). In other words, the second output module (1356) may make ad hoc adjustments in real time to automatically adjust the frequency, waveform, and / or other parameters of its own output, thereby avoiding amplification, cancellation, interference, and / or other interactions with the sensed output of the first output module (1354). For example, if the sensor module (1360) determines that the first output module (1354) is outputting a 400 kHz unipolar RF signal, the second output module (1356) may adjust its own bipolar RF output signal to 800 kHz or 1 MHz to properly distinguish the signals. In some variations, a frequency multiplier circuit (e.g., a two-diode odd-order frequency multiplier, etc.) may be utilized with a single generator output module.

[0110] While the above-described embodiments shown in Figures 21-22 are illustrated in connection with handheld instruments (1220, 1221, 1320, 1321), the same teachings may readily be applied in connection with robotically controlled instruments, including, but not limited to, those described above and in the various references cited herein. Similarly, while the above-described embodiments shown in Figures 21-22 are illustrated in connection with external generators (1210, 1310) coupled to the instruments (1220, 1221, 1320, 1321) via cables (1230, 1231, 1330, 1331), the same teachings may readily be applied in connection with instruments having integrated generators (1210, 1310) housed within the body of the instrument. An example of such a scenario may include an instrument having an end effector operable to apply two or more types of energy modalities (e.g., monopolar RF, bipolar RF, ultrasound, etc.), with two or more corresponding types of generators housed within the body of the instrument to drive those two or more energy modalities.

[0111] VII. EMBODIMENTS OF ELECTROSURGICAL INSTRUMENTS WITH SHAFT VOLTAGE MONITORS The following description relates to examples of different features that may be incorporated into any of the various surgical systems described above. Accordingly, the features described below may be combined in various permutations, as will become apparent to those skilled in the art in light of the teachings herein. Similarly, various ways in which the features described below may be incorporated into any of the various surgical systems described above will become apparent to those skilled in the art in light of the teachings herein. It should be understood that the features described below may be incorporated into robotically controlled surgical instruments and / or handheld surgical instruments.

[0112] Some variations of the instruments described herein may provide a floating ground for conductive components within the instrument shaft assembly. In scenarios where a floating ground exists, such conductive components are not electrically coupled to ground. The floating ground may separate ground return paths within the instrument and converge them, effectively creating an ad hoc ground that is isolated from the actual ground. The floating ground may have an associated ad hoc voltage, and a control circuit may regulate the voltage associated with the floating ground. Finally, the floating ground may provide electrical isolation for components in an electrical circuit where no earth ground exists. A conductive component may be understood to have a floating potential or voltage when such a conductive component is not electrically coupled to ground.

[0113] Some aspects of the present disclosure are presented to monitor voltage potentials at components of a shaft assembly and adaptively adjust power, adjust sense signals, and / or provide some other type of system response based on the detected voltage potentials at the components of the shaft assembly. The voltage potential of one shaft component may be monitored relative to a common return path and relative to the potentials of other shaft components. In some cases, fluctuations in voltage potentials present in different components of an electrosurgical system can cause ground loops. For example, a potential difference between the return path ground on the generator and a local ground on an end effector in use can cause a ground loop. The impact of a ground loop can depend on the severity of the potential difference between the grounds. A small ground loop can inject noise into the system and cause an interruption or loss of communication on data lines. A large ground loop can damage electronic components or reset the entire system, rendering it temporarily inoperable. Therefore, it may be desirable to actively monitor voltage fluctuations and take corrective action.

[0114] As described in more detail below, potential or voltage fluctuations may be monitored to control electrical connections to components to drain or float undesired voltages to a return path based on a comparison of the measured voltage potential with a predetermined maximum threshold. In some cases, shaft components and / or control electronics may be intermittently shifted between an electrically floating state and an interconnected state. Such shifts may ensure accurate local measurements by sensors and accurate operation by active electrical components, allow for the draining of otherwise parasitic power signals, and / or prevent accidental, unintended charging of system components. In some cases, local sensing may be paused or adjusted while voltages are drained as part of a safety drain process, as described herein. Corrective actions may include any one or more of adjusting noise correction thresholds, adjusting conversions to correct introduced errors, providing a “blackout” to the system that requires sensors to be ignored within the scope of the potential shift’s impact, or even restarting or shutting off power to the sensors to protect them from damage.

[0115] In some variations, monitoring the variation in electrical potential may include monitoring the shaft components for voltage potential relative to each other and / or relative to a return path to the generator. For example, in variations in which the shaft assembly is constructed of multiple metal components, the instrument may include a wiring harness or flex circuit for connecting the end effector to the outer housing assembly.

[0116] FIG. 23 illustrates a portion of the instrument 1400, including the elongated shaft 1410. While the instrument 1400 is illustrated and described in detail, it should be understood that various other electrosurgical instruments are contemplated, including, but not limited to, the instruments described above. The console (not shown) of the instrument 1400 can receive voltage measurements from one or more sensors and react accordingly to initiate corrective action, as described below. By way of example only, the console may be configured similarly to the console 20 described above with reference to FIG. 1 and may include a data processor configured and operative to initiate corrective action, adjust the power profile transmitted to the instrument 1400, or float or drain any of the components forming the body of the instrument 1400. Furthermore, the console may be a component of a robotic electrosurgical system, as described above. Various suitable forms that the console of the instrument 1400 may take will be apparent to those skilled in the art in light of the teachings herein.

[0117] The instrument (1400) of this example is substantially similar to the instrument (600) of FIG. 9 described above, except for the differences described below. The instrument (1400) includes a first articulating segment (1412) and a second articulating segment (1414). An end effector (1420) is positioned at the distal end of the second articulating segment (1414). The end effector (1420) of this example includes a pair of jaws (1422, 1424) operable to pivot toward and away from each other to grasp tissue. In some variations, one or both of the jaws (1422, 1424) include one or more electrodes operable to apply RF energy to tissue, as described herein. Such electrodes may be powered via electrical connectors (1404, 1406), which are routed through the instrument via a wiring harness (1402). While a wiring harness 1402 is used in this example, any other suitable type of conductor assembly (e.g., flex circuit ribbon, etc.) may be used, as would be apparent to one of ordinary skill in the art in view of the teachings herein. Additionally or alternatively, the end effector 1420 may include an ultrasonic blade and / or various other features in addition to or instead of including the jaws 1422, 1424. The segments 1412, 1414 may be operable to pivot relative to the shaft 1410 and relative to each other, thereby deflecting the end effector 1420 laterally away from or toward the central longitudinal axis of the shaft 1410.

[0118] The instrument 1400 of this example further includes a first set of wires 1430 extending through the shaft 1410, a second set of wires 1432 extending through the shaft 1410 and both segments 1412, 1414, and a third set of wires 1434 further extending through the shaft 1410 and both segments 1412, 1414. The wire sets 1430, 1432, 1434 may be operable to control the movement of the segments 1412, 1414 relative to the shaft 1410. For example, power may be transmitted along one or more of the wire sets 1430, 1432, 1434 to selectively engage or disengage a corresponding clutch mechanism, thereby actively driving lateral deflection of one or both of the segments 1412, 1414 relative to the shaft 1410 and / or rotation of one or both of the segments 1412, 1414 relative to the shaft 1410. Alternatively, power may be transmitted along one or more of the wire sets 1430, 1432, 1434 to drive a corresponding solenoid, motor, or other feature to actively drive lateral deflection of one or both of the segments 1412, 1414 relative to the shaft 1410 and / or rotation of one or both of the segments 1412, 1414 relative to the shaft 1410. In a variation in which the end effector (1420) is operable to apply RF energy to tissue, one or more additional wire sets, such as a wiring harness (1402), in addition to the wire sets (1430, 1432, 1434), extend along the shaft (1410) and segments (1412, 1414) and couple to the connectors (1404, 1406) to provide power to the end effector (1420).

[0119] The connectors 1404, 1406 in this example include a proximal connector 1404 and a distal connector 1406 configured to removably mate with one another. The wiring harness 1402 is coupled to the proximal connector 1406 such that the wires 1450, 1542 of the wiring harness 1402 mate with the distal connector 1404, which in turn is configured to mate with the proximal connector 1406 to provide power to the end effector 1420. By way of example only, such power may include bipolar RF energy for electrodes on the end effector 1420. The return path ground 1452 (e.g., a ground wire, ground trace, etc.) from the end effector 1402 may have intermediate electrical connections to metal components within the shaft assembly, such as the shaft 1410, first articulation segment 1412, and second articulation segment 1414, so that the voltage potential of each component 1410, 1412, 1414 relative to the return path 1452 and relative to each other component 1410, 1412, 1414 can be monitored. This monitoring can be used by the console to control the electrical connections to the components 1410, 1412, 1414 to allow them to be electrically drained or floated relative to the return path 1452 based on a comparison of the measured voltage potential with a predetermined maximum threshold voltage value.

[0120] As shown, a wiring harness 1402, or alternatively a flexible circuit, connects the end effector 1420 to the handle or other body of the electrosurgical instrument 1400 and may include conductive attachment points 1460, 1462, 1464 to conductive structure within the instrument 1400. These conductive attachment locations 1460, 1462, 1464 may enable integrated sensors 1466, 1468, 1470 to monitor the voltage potentials of components 1410, 1412, 1414, respectively, as they relate to control electronics (e.g., a generator or related components) and return path ground 1452. In this example, sensors 1466, 1468, 1470 are integrated adjacent to corresponding attachment locations 1460, 1462, 1464, although other configurations may be used. By way of example only, wires, conductive traces, or other conductive paths may extend from each attachment location (1460, 1462, 1464) to a proximal location (e.g., a proximal portion of shaft (1410), a body of instrument (1400) proximal to shaft (1410), a console coupled to instrument (1400), etc.) and be coupled to return path (1452) at such proximal location to effectively monitor the electrical potential between attachment locations (1460, 1462, 1464) and return path (1452).

[0121] If the system detects a potential change in one of the components (1410, 1412, 1414), the system can determine whether the potential change exists due to an externally applied voltage source or from capacitive coupling between the component (1410, 1412, 1414) and another component (1410, 1412, 1414) that has been intentionally activated with power. Once the system determines the source of the voltage fluctuation, the system can actively ground or clamp off the voltage potential, alert the user of external contact with another energized instrument, and / or apply adjustments to the rest of the sensors (1466, 1468, 1470) proportional to the effect caused by one sensed potential. In some variations, the sensors (1466, 1468, 1470) include high-impedance sensors positioned between the metal frame components (1410, 1412, 1414) and the return path (1452). In variations utilizing flexible circuits instead of wiring harness (1404), wires (1450, 1542) may instead be included as conductive traces routed through the body of device (1400).

[0122] In some variations, sensors (1466, 1468, 1470) are configured to monitor the voltage potential of all metal shaft components, such as components (1410, 1412, 1414), relative to the ground path (1452) and selectively ground and remove only those that have accumulated current. Therefore, to operate in the safest configuration, each component (1410, 1412, 1414) may remain electrically floating unless the particular component (1410, 1412, 1414) requires discharge. In this context, "electrically floating" means that the component (1410, 1412, 1414) is not electrically coupled to ground. In some scenarios, the electrically floating component (1410, 1412, 1414) may have a certain floating voltage. Such a floating voltage may be induced by an electromagnetic field generated within the component (1410, 1412, 1414) by an adjacent activated component. Such floating voltages can also be caused by charge buildup within the components (1410, 1412, 1414).

[0123] In some variations, each component (1410, 1412, 1414) may be shifted from an electrically floating configuration to an interconnected configuration, with one or more components (1410, 1412, 1414) being at least temporarily electrically coupled to one another. This may be done intermittently to ensure accurate local measurements and operation while still allowing the system to drain any parasitic or accidental charge. Thus, each component (1410, 1412, 1414) may be maintained in an electrically floating state by default and may be grounded through the console only when it is determined that a particular component (1410, 1412, 1414) has accumulated a potential above a threshold and therefore should be discharged.

[0124] As previously mentioned, the shaft 1410 and / or the end effector 1420 may include one or more motion sensors operable to sense one or more parameters associated with the motion of the end effector 1420. By way of example only, such motion sensors may include a force sensor (e.g., force sensor 114) operable to sense a clamping force being applied to tissue by the jaws 1422, 1424 or a force sensor operable to sense a lateral load applied to the shaft 1410 during engagement of tissue by the end effector 1420. By way of further example only, the motion sensors may include a temperature sensor operable to sense the temperature of the end effector 1420 or the temperature of tissue engaged by the end effector 1420. As another illustrative example only, the motion sensors may include an impedance sensor operable to sense the impedance of tissue engaged by the end effector 1420. As yet another merely illustrative example, motion sensors may include position sensors (e.g., position sensor 112), sensors 720, 722, 724, sensors 770, 772, etc.) operable to sense the position or orientation of shaft 1410 and / or end effector 1420. Various types of motion sensors that may be incorporated into shaft 1410 and / or end effector 1420 will be apparent to those skilled in the art in view of the teachings herein.

[0125] In variations of instruments (1400) having motion sensors, such as those described above, the voltage shifts described herein can ensure accurate local measurements by such motion sensors and reduce noise that might otherwise occur in signals from such motion sensors. In some cases, sensing by the motion sensors may be paused or adjusted while the voltage is drained as part of a safety drain process as described herein. Corrective action may also include any one or more of adjusting noise correction thresholds, adjusting conversions to correct for introduced errors, providing a “blackout” to the system that requires signals from the motion sensors to be ignored within the scope of the potential shift effect, or even restarting or cutting power to the motion sensors to protect them from damage.

[0126] In some variations, sensors (1466, 1468, 1470) and / or any other sensors in shaft (1410) or end effector (1420) may be suspended or otherwise deactivated and disconnected while one or more of components (1410, 1412, 1414) are at least temporarily grounded, whether such ground connection is made through another component (1410, 1412, 1414), through a dedicated ground path (1452), or through any other already grounded component of instrument (1400).

[0127] In some instruments, such as a bipolar RF surgical stapling instrument with an end effector having a bipolar electrode near a surgical staple, there is a risk that the bipolar electrode may come into contact with the surgical staple, potentially creating a short circuit between the bipolar electrodes through one or more surgical staples. In monopolar instruments, capacitively coupled currents may build up on any metal components forming the instrument shaft. To mitigate the risks associated with these scenarios, plastic components (or “metal insert interruptions”) may be included within the shaft assembly to avoid having a shaft that is metal along its entire length. For example, an electrically insulating member may be included in one or more of the components (1410, 1412, 1414) to minimize the impact of these current risks on surrounding components and further minimize the propagation of capacitively coupled currents upstream and downstream of the instrument (1400). Molded plastic or otherwise non-conductive members may be inserted where the metal portions of the components (1410, 1412, 1414) overlap. In such variations, the shaft assembly may lack a continuous path for unintended electrical conduction along its entire length (other than such paths as are intentionally provided by wires, etc.). In other words, conductive structural components of the shaft assembly that are not intended to conduct electricity may include non-conductive structural components inserted between them to provide interruptions that disrupt electrical conduction that might otherwise exist. In some variations, adjacent components (1410, 1412, 1414) may include holes or keying features that allow one long non-conductive plate to be coupled to another via interlocking injection-molded plastic sections. Other suitable ways in which electrically isolated non-conductive structural components may be integrated into the shaft assembly will be apparent to those skilled in the art in view of the teachings herein.

[0128] VIII. EMBODIMENTS OF ELECTROSURGICAL INSTRUMENTS WITH ELECTRICAL RESISTANCE MONITORS AT ROTARY COUPLINGS The following description relates to examples of different features that may be incorporated into any of the various surgical systems described above. Accordingly, the features described below may be combined in various permutations, as will become apparent to those skilled in the art in light of the teachings herein. Similarly, various ways in which the features described below may be incorporated into any of the various surgical systems described above will become apparent to those skilled in the art in light of the teachings herein. It should be understood that the features described below may be incorporated into robotically controlled surgical instruments and / or handheld surgical instruments.

[0129] As mentioned above, some instruments may include a joint within a shaft assembly, such as one component of the shaft assembly articulating relative to another component at a pivot point within the shaft assembly, or one component of the shaft assembly rotating about a central longitudinal axis relative to another component of the shaft assembly. An example of a rotational coupling joint within a shaft assembly is described above in connection with the instrument (600) shown in FIG. 9, although other examples will be apparent to those skilled in the art in light of the teachings herein. An example of a pivotal articulation joint within a shaft assembly is described above in connection with the shaft assembly (750) shown in FIG. 11, although other examples will be apparent to those skilled in the art in light of the teachings herein. In variations of instruments having telescoping shaft assembly components, one component of the shaft assembly may translate relative to another component of the shaft assembly, thereby changing the effective length of the shaft assembly.

[0130] Whether an instrument includes a rotary joint, a pivot joint, a telescoping joint, and / or some other type of joint, it may be necessary to provide electrical communication across such joints. For example, such electrical communication may include communicating RF power from the console to the end effector through one or more movable joints in the shaft assembly. Such electrical communication may also include providing a common ground return path along the length of the shaft assembly (e.g., from the end effector to the console), which must pass through one or more movable joints in the shaft assembly. Such electrical communication may also include communicating signals from sensors in the end effector or distal portion of the shaft assembly to the console through one or more movable joints in the shaft assembly. While merely illustrative examples of sensors that may be included in a shaft assembly are described above in connection with shaft assembly (700) shown in FIG. 10 and shaft assembly (750) shown in FIG. 11, other ways in which sensors may be integrated into the shaft assembly or end effector will become apparent to those skilled in the art in view of the teachings herein. For example, in an end effector that includes electrodes for applying bipolar RF energy to tissue, these same electrodes may be used as sensors for sensing impedance in the tissue being contacted by the end effector. Regardless of what the electrical coupling is used for, the movable joint of the shaft assembly may include one or more slip couplings (e.g., slip rings and corresponding leaf springs or other sliding contacts, etc.) or other types of couplings configured to provide electrical continuity across the joint without compromising the freedom of movement at the joint.

[0131] In some scenarios, the electrical communication characteristics of electrical couplings in such fittings may change during use of the instrument. For example, such electrical couplings may be exposed to tissue debris, saline, bodily fluids, or other fluids during a surgical procedure, since it may be difficult to obtain a fluid-tight seal at such couplings. If such debris or fluids are conductive or at least semi-conductive, the intrusion of such debris or fluids through the fittings may eventually reach the electrical couplings of the fittings, thereby contaminating the electrical couplings and affecting the electrical communication characteristics of those electrical couplings. This may include affecting the resistance and / or voltage at the fittings. This may then introduce noise into electrical signals communicated across the fittings or, in some cases, cause signal loss across the fittings. Contamination of the electrical couplings may also cause shorts between contacts, heating of contaminants, and / or heating of the fittings. This unwanted heat may cause unwanted tissue trauma or other undesirable effects in the surgical field, adversely affect the operability of the instrument, and / or damage one or more components of the instrument. In some cases, as the electrical resistance at the electrical coupling of a movable joint increases, the heat generated at the electrical coupling increases, and therefore, an increase in the resistance of the electrical coupling of a movable joint can indicate the amount of heat generated when an electrical signal or power passes through that electrical coupling.

[0132] In view of the above, it may be desirable to monitor changes in electrical properties (e.g., voltage, electrical resistance, etc.) of electrical couplings (e.g., slip couplings, etc.) in movable joints (e.g., rotary joints, pivot joints, telescoping joints, etc.) within an instrument and provide an automated response in real time to detected changes. Such responses may include adjusting generator power levels, signal processing magnitudes, etc. In some cases, changes in the resistance of a monitored component may result from positional changes of instrument components (i.e., changes in angular orientation of components relative to one another, changes in joint angles, etc.), and if monitoring determines that an electrical coupling of a joint is contaminated, the console may vary the power output during operation based on the positional change of a particular component. Examples of how such monitoring and responses may be performed are described in more detail below.

[0133] FIG. 24 illustrates one embodiment of the monitoring system described above. As shown in FIG. 24, the instrument (1500) includes an elongate shaft (1510). While the instrument (1500) is illustrated and described in detail, various other electrosurgical instruments are contemplated, including, but not limited to, the instruments described herein. The instrument (1500) includes a first articulating segment (1512) and a second articulating segment (1514). An end effector (1520) is positioned at the distal end of the second articulating segment (1514). The end effector (1520) of this example includes a pair of jaws (1522, 1524) operable to pivot toward and away from each other to grasp tissue. In some variations, one or both of the jaws (1522, 1524) include one or more electrodes operable to apply RF energy to tissue, as described herein. Additionally or alternatively, the end effector (1520) may include an ultrasonic blade and / or various other features.

[0134] The segments 1512, 1514 may be operable to pivot relative to the shaft 1510 and relative to each other, thereby defining joints 1550, 1552, respectively, to deflect the end effector 1520 laterally away from or toward the central longitudinal axis 1504 of the shaft 1510. Additionally or alternatively, one or both of the segments 1512, 1514 may be operable to rotate relative to the shaft 1510 about the central longitudinal axis 1504. Thus, the joints 1550, 1552 may constitute a pivotal articulation joint and / or a rotational joint. In either case, the joints 1550, 1552 may each include one or more slip joints or other types of electrical couplings configured to provide electrical continuity across the joints 1550, 1552 without compromising the freedom of movement at the joints 1550, 1552. Such electrical couplings may provide for the communication of RF power to the end effector 1520, provide a ground return path across the joints 1550, 1552, provide for the communication of electrical signals from one or more sensors in the end effector 1520 and / or segments 1512, 1514, and / or provide any other type of electrical communication.

[0135] A console or other processing module of instrument 1500 may receive resistance, voltage, temperature, and / or other types of measurements from one or more sensors and react accordingly to initiate corrective action, as described below. By way of example only, such a console or other processing module may be configured similarly to console 20 described above with reference to FIG. 1 or other console or control circuitry described herein, and may include a data processor configured and operable to initiate corrective action, adjust the power profile transmitted to instrument 1500, or drain any excess energy stored within instrument 1500. Additionally, the console or other processing module may be a component of a robotic electrosurgical system, as described above.

[0136] The instrument 1500 of this example further includes a first set of wires 1530 extending through the shaft 1510, a second set of wires 1532 extending through the shaft 1510 and both segments 1512, 1514, and a third set of wires 1534 further extending through the shaft 1510 and both segments 1512, 1514. The wire sets 1530, 1532, 1534 may be operable to control the movement of the segments 1512, 1514 relative to the shaft 1510. For example, power may be transmitted along one or more of the wire sets 1530, 1532, 1534 to selectively engage or disengage a corresponding clutch mechanism, thereby actively driving lateral deflection of one or both of the segments 1512, 1514 relative to the shaft 1510 and / or rotation of one or both of the segments 1512, 1514 relative to the shaft 1510. Alternatively, power may be transmitted along one or more of the wire sets 1530, 1532, 1534 to drive a corresponding solenoid, motor, or other feature to actively drive lateral deflection of one or both of the segments 1512, 1514 relative to the shaft 1510 and / or rotation of one or both of the segments 1512, 1514 relative to the shaft 1510. One or more additional wires may also provide RF power (bipolar RF and / or monopolar RF) to end effector 1520. Additionally or alternatively, one or more additional wires may also provide for communication of electrical signals from one or more sensors in end effector 1520 and / or segments 1512, 1514.

[0137] Additionally, in this embodiment, one or more additional wire sets, such as a wiring assembly 1502, extend along the shaft 1510 to provide voltage, electrical resistance, temperature, and / or other measurements of the joints 1550, 1552 to a console or other processing module. The wiring assembly 1502 may include power lines 1554 for the sensors 1566, 1568 and a return path line 1556. The wiring assembly 1502 may have intermediate connections positioned at the respective joints 1550, 1552 adjacent the first articulation segment 1512 and the second articulation segment 1514 so that voltage, electrical resistance, temperature, and / or other parameter(s) of the joints 1550, 1552 can be monitored. As shown, the wiring assembly (1502), or alternatively a flexible circuit, connects integrated sensors (1566, 1568) to monitor variations in voltage, electrical resistance, temperature, and / or other parameter(s) of the fittings (1550, 1552).

[0138] As described above, debris or fluid contamination at the fittings (1550, 1552) can affect the electrical communication characteristics (e.g., resistance, voltage, etc.) of the electrical couplings at the fittings (1550, 1552). By monitoring the electrical communication characteristics (e.g., resistance, voltage, etc.) at the fittings (1550, 1552), the console or other processing module can provide a real-time comparison between the monitored electrical communication characteristic value and a predetermined value or range and provide automatic corrective action or other response in real time when the monitored electrical communication characteristic value deviates from the predetermined value or range. Alternatively, the console or other processing module can provide any other suitable type of response, examples of which are described in more detail below. If the console or other processing module detects a change in voltage, electrical resistance, temperature, and / or other parameter at one of the fittings (1550, 1552), the console or other processing module can then determine whether the variation is within a predetermined deviation range indicating that corrective action is warranted.

[0139] By way of example only, monitoring at the above-described joints 1550, 1552 may be used by a console or other processing module to control the power supplied to the end effector 1520 based on variations in voltage, electrical resistance, temperature, and / or other parameter(s) measured adjacent one or more of the joints 1550, 1552. Additionally or alternatively, the console or other processing module may match the resistance provided through the return path wire 1556 (e.g., to the resistance of the power wire 1554) to sufficiently bleed off current and prevent damage to the instrument 1500 due to an inadvertent electrical short. By monitoring the resistance and / or other electrical parameters at the joints 1550, 1552 over time, the console or other processing module may adjust the maximum power limit sent to the end effector 1520 to prevent the instrument 1500 from overheating or being damaged. Additionally, the generator may selectively increase or decrease power as needed based on the above-described monitoring at the joints (1550, 1552) to provide a constant or predictable thermal effect at the end effector (1520).

[0140] In addition to or instead of monitoring electrical parameters at the joints (1550, 1552), sensors (1566, 1568) may monitor temperatures at the joints (1550, 1552). Whether or not electrical parameters at the joints (1550, 1552) are monitored, monitoring temperatures at the joints (1550, 1552) may enable a console or other processing module to further adjust the delivery of power (e.g., bipolar RF, monopolar RF, etc.) to the end effector (1520) without generating excessive heat in the joints (1550, 1552) that could otherwise cause undesired tissue trauma or other undesirable effects in the surgical field, adversely affect the operability of the instrument (1500), and / or damage one or more components of the instrument (1500) at or near the joints (1550, 1552). By way of example only, the generator may adjust the frequency or maximum duty cycle of the applied energy, rather than simply adjusting the power level, in response to the monitored temperature of the joints (1550, 1552) exceeding a predetermined threshold.

[0141] While the foregoing examples have been described in connection with contaminants reaching the electrical connections through the joints (1550, 1552) and having undesirable electrical and / or thermal effects, normal operation of the instrument (1500) can also ultimately result in undesirable electrical and / or thermal effects at the electrical connections of the joints (1550, 1552) (even in the absence of contaminants at the joints (1550, 1552)). For example, transmission of bipolar or monopolar RF energy through electrical connections (e.g., slip joints, etc.) at the joints (1550, 1552) can result in heating of these electrical connections. Such heating can represent a power loss, with the RF electrode(s) of the end effector (1520) not receiving an adequate amount of power. In such a scenario where the sensors (1566, 1568) sense such heat-based losses, the console or other processing module may gradually increase the level of power delivered from the generator as needed based on the monitored parameters at the joints (1550, 1552) to provide predictable and user-expected results on the tissue engaged by the end effector (1520). For example, these results may include predictable and user-expected tissue sealing, ablation, etc.

[0142] While it may be appropriate to gradually increase the level of power delivered from the generator to compensate for heat losses at the joints 1550, 1552, the process may reach a point where this type of response is no longer feasible. For example, increasing the power level beyond a certain point may result in damage to the instrument 1500, abnormal or undesirable tissue effects from the end effector 1520, unreliable feedback from one or more sensors in the instrument 1500, and / or other undesirable effects. Thus, the console or other processing module may gradually increase the level of power delivered from the generator as one or more monitored parameters at the joints 1550, 1552 vary through a range, but then provide a different type of response if one or more monitored parameters at the joints 1550, 1552 exceed a predetermined threshold. For example, if a monitored parameter at one or both of the fittings (1550, 1552) exceeds a predetermined threshold (e.g., maximum electrical resistance, maximum temperature, etc.), the console or other processing module may provide corrective action.

[0143] In some variations, corrective action includes transitioning the instrument 1500 into an alternate operating mode, "limp mode." By way of example only, "limp mode" may allow some degree of continued use of the instrument 1500, but the console or other processing module may begin reducing power to the problematic joint 1550, 1552 to keep it below maximum temperature (e.g., to prevent catastrophic failure of the problematic joint 1550, 1552, to prevent the problematic joint 1550, 1552 from burning tissue in the surgical field, etc.). Such power reduction may at least temporarily adversely affect the ability of the end effector 1520 to impart the desired RF effect to tissue. Thus, if the console or other processing module determines that a "limp mode" or other alternate operating mode is required in light of monitored parameters exceeding predetermined thresholds in one or both of the fittings (1550, 1552), the console or other processing module may provide an alert (e.g., audible, visual, tactile, etc.) to the operator, thereby notifying the operator that the operating mode of the instrument (1500) is changing. This may allow the operator to adjust the surgical technique accordingly, which may include at least momentarily deactivating RF power to allow the problematic fittings (1550, 1552) to cool. The operator may also wish to clean or replace the instrument (1500) in response to receiving a "limp mode" alert.

[0144] In some variations, the sensors (1566, 1568) of the instrument (1500) may be configured to monitor the resistance or voltage of the fittings (1550, 1552) over time and adjust or control the response of the power signal based on deviations beyond an expected range as an effect from external voltages or potentials, thereby generating an offset in the power signal. Contamination of the fittings (1550, 1552) can change the resistance of the electrical bonds within the fittings (1550, 1552), as described above. This can introduce electrical noise into the power or sensor signal or potentially result in signal loss. If a local AC load is introduced as a measure of the change in overall system resistance, the sensors (1566, 1568) can be adjusted to compensate for the presence of contamination.

[0145] In some variations, the instrument 1500 includes one or more operating parameter sensors (other than sensors 1566, 1568) operable to sense various operating parameters associated with the instrument 1500. Such operating parameters may include, but are not limited to, position or orientation information regarding one or more components of the instrument 1500, electrical or thermal properties of tissue engaged by the end effector 1520, and the like. Some merely illustrative examples of position or orientation sensors that may be included in a shaft assembly are described above in connection with the shaft assembly 700 shown in FIG. 10 and the shaft assembly 750 shown in FIG. 11. As another merely illustrative example, the end effector 1520 may include electrodes for applying bipolar RF energy to tissue, and these same electrodes may be used as sensors for sensing impedance within tissue contacted by the end effector 1520. Other ways in which operational parameter sensors may be integrated into the shaft assembly or end effector, and other operational parameters that may be sensed by such operational parameter sensors, will be apparent to those skilled in the art in view of the teachings herein. Contamination at the joints (1550, 1552) can adversely affect the signals from such operational parameter sensors, such as by introducing noise into or otherwise compromising the reliability of the signals from such operational parameter sensors.

[0146] Regardless of the location or specific operating parameters sensed by such operating parameter sensors, the console or other processing module may vary its processing of signals from such operating parameter sensors based at least in part on feedback from sensors (1566, 1568) indicating contamination at fittings (1550, 1552) or other conditions that may adversely affect the signals from the operating parameter sensors. For example, if data from one or both of sensors (1566, 1568) indicates a value (e.g., voltage, resistance, etc.) that exceeds a first threshold such that the signal from the primary operating parameter sensor is somewhat affected, the console or other processing module may continue to factor the signal from the affected primary operating parameter sensor as part of a control algorithm, but may additionally rely on signals from one or more secondary operating parameter sensors to execute the control algorithm. In some such scenarios, the signals from one or more secondary operating parameter sensors may be signals that a console or other processing module would typically not factor as part of a control algorithm in the absence of an affected primary operating parameter sensor, and so the signals from one or more secondary operating parameter sensors are factored into the control algorithm only because the signals from sensors (1566, 1568) indicate that the signals from the primary operating parameter sensors may be noisy or otherwise somewhat inaccurate. Thus, in this scenario, the affected primary operating parameter sensors may still affect the control algorithm, but the signals from the affected primary operating parameter sensors are now supplemented by signals from one or more secondary operating parameter sensors.

[0147] If data from one or both of the sensors (1566, 1568) indicates a value (e.g., voltage, resistance, etc.) above a second threshold such that the signal from the primary operating parameter sensor is substantially affected, the console or other processing module may begin to ignore the signal from the primary operating parameter sensor. In other words, the console or other processing module may suspend adjustments to a component (e.g., a generator, etc.) whose output would otherwise be adjusted in response to a signal from the affected primary operating parameter sensor. Alternatively, in a situation where the console or other processing module begins to ignore the signal from the primary operating parameter sensor, the console or other processing module may begin to rely again on signals from one or more secondary operating parameter sensors to drive its control algorithms (i.e., as a replacement for the currently ignored signals from the primary operating parameter sensor). Thus, the signals from the one or more secondary operating parameter sensors may serve as proxies for the signals from the primary operating parameter sensor. In such a scenario, the one or more secondary operating parameter sensors may sense parameters related to, but different from, the parameters sensed by the primary operating parameter sensor. Alternatively, the console or other processing module may apply some other predetermined control algorithm to the output of the component that would otherwise be adjusted based on the signal from the affected operating parameter sensor.

[0148] In one merely illustrative example of an instrument having a primary operating parameter sensor and a secondary operating parameter sensor, the instrument includes an end effector having a sensor that senses the density or other characteristic of tissue clamped between the jaws of the end effector. This may function as the primary operating parameter sensor. An electrical signal path between this primary operating parameter sensor in the end effector and a corresponding control module may include a rotational slip coupling in a distal portion of the instrument shaft assembly. The instrument may also include a translating knife member that cuts tissue captured between the jaws of the end effector. The knife member may be driven by a motor. A control algorithm for the motor may factor the density or other characteristic of the tissue clamped between the jaws of the end effector, just as the control algorithm factors the signal from the primary operating parameter sensor in the end effector. If a signal from a separate sensor (e.g., similar to sensors (1566, 1568)) monitoring a parameter associated with the slip joint exhibits a value (e.g., voltage, resistance, etc.) above a second threshold, thereby indicating contamination of the slip joint and thereby indicating that the signal from the primary operating parameter sensor in the end effector is no longer necessarily reliable, the control module may switch to a secondary operating parameter sensor to either supplement or replace the signal from the primary operating parameter sensor. In this example, the secondary operating parameter sensor may include a motor current sensor operable to sense a current used to drive a motor driving the knife member. Because knife member motion may vary based on the characteristics of the tissue clamped between the jaws of the end effector, the signal from the motor current sensor may serve as an appropriate proxy for the signal from the primary operating parameter sensor in the end effector.

[0149] If the control module begins factoring the signal from the secondary operating parameter sensor into the control algorithm as a supplement or replacement for the signal from the primary operating parameter sensor based on data from one or both of the sensors (1566, 1568) indicating that a value (e.g., voltage, resistance, etc.) exceeds a threshold value and the signal from the primary operating parameter sensor is being adversely affected, the console or other processing module may continue to monitor the data from one or both of the sensors (1566, 1568). In some such scenarios, the data from one or both of the sensors (1566, 1568) may indicate that the corresponding monitored value (e.g., voltage, resistance, etc.) no longer exceeds a threshold value and therefore the signal from the primary operating parameter sensor is no longer being adversely affected. This may occur, for example, if contaminants are removed from the fittings (1550, 1552) while the instrument (1500) is in use. When this occurs, the control module may revert to the signal from the primary operating parameter sensor to drive the control algorithm and may stop factoring the signal from one or more secondary operating parameter sensors into the control algorithm.

[0150] In some cases, variations in electrical resistance at the slip joints within joints (1550, 1552) may also provide feedback indicative of the level of torque being applied at joints (1550, 1552). As another merely exemplary alternative, variations in electrical resistance at the slip joints within joints (1550, 1552) may also provide feedback indicative of the angular position of the components at joints (1550, 1552). For example, in a variation in which joints (1550, 1552) include a slip joint circular race that terminates at one angle (e.g., 5 degrees), the resistance value may then drop at a corresponding angle of rotation (e.g., 175 degrees), and then the resistance in the track may change as the joint is rotated. This additional resistance loss may be tracked over time and used to determine what angle the slip joint is at relative to the other side of the joint, as well as to compensate for the loss and turn it off if the loss is too great.

[0151] FIG. 25 shows a flow diagram of an exemplary method (1600) for monitoring temperature and resistance at a joint of a surgical instrument, as described above. While temperature and resistance are monitored in this example, any other suitable parameter (e.g., voltage, etc.) may be monitored in addition to or instead of monitoring temperature and / or resistance. In step (block 1602), the system or an operator initiates power output from the generator to the end effector. During operation, in step (block 1604), sensors (1566, 1568) measure the resistance and temperature at a joint, such as one of joints (1550, 1552), and determine whether the measured resistance and temperature vary from normal within a predetermined range. If the resistance and temperature vary from normal are not within the predetermined range, the sensor sends a signal back to the console, and in step (block 1606), the console adjusts the generator output power accordingly. Alternatively, in some variations, the console stores known normal resistance and temperature values, and the sensor is configured to continuously measure and transmit the measured resistance and temperature values ​​to the console. In some such scenarios, the console makes a determination as to whether the resistance and temperature variations from normal are within predetermined ranges.

[0152] If the resistance and temperature variations from normal are within predetermined ranges in step (block 1604), the method moves to the next one of the fittings (1550, 1552) and makes the same measurements and determinations in step (block 1608). If the resistance and temperature variations from normal are not within predetermined ranges, the sensor sends a signal back to the console, and again in step (block 1606), the console adjusts the generator output power accordingly. Thereafter, in step (block 1610), each additional fitting is measured and corrective action is taken following the same method as steps (blocks 1604, 1608).

[0153] IX. EMBODIMENTS OF ELECTROSURGICAL INSTRUMENTS WITH MODULAR COMPONENT CONTACT MONITORING The following description relates to examples of different features that may be incorporated into any of the various surgical systems described above. Accordingly, the features described below may be combined in various permutations, as will become apparent to those skilled in the art in light of the teachings herein. Similarly, various ways in which the features described below may be incorporated into any of the various surgical systems described above will become apparent to those skilled in the art in light of the teachings herein. It should be understood that the features described below may be incorporated into robotically controlled surgical instruments and / or handheld surgical instruments.

[0154] As discussed above in connection with the instrument (900) shown in FIG. 15 , some instruments may include modular component interfaces, such as shaft interface assemblies (920), having multiple electrical contacts positioned closely together, such as electrical contacts (924). Such configurations may present risks of signal crosstalk, electrical shorts, or other signal interference from capacitively coupled currents or high voltages occurring across such closely positioned electrical contacts of the modular component interfaces. In some scenarios, these issues may result from the difficulty of providing a complete fluid seal near the electrical connectors and their associated contact arrays. Fluid present at the electrical contact interface may attenuate transmitted signals or create electrical bridges between contacts that are not intended to be bridged. Therefore, it may be desirable to protect or reinforce the electrical contacts of a modular shaft or end effector from capacitively coupled currents or high voltages, and / or to monitor the electrical contacts and take corrective action as necessary.

[0155] Some instruments include features for protecting electrical connectors or modular components within a surgical instrument. Examples of such devices and related concepts are disclosed in U.S. Patent Nos. 10,090,616, entitled "Surgical Instrument Handle Assembly with Feature to Clean Electrical Contacts at Modular Shaft Interface," issued October 2, 2018; 10,813,640, entitled "Method of Coating Slip Rings," issued October 27, 2020; and 10,639,038, entitled "Staple Cartridge with Short Circuit Prevention Features," issued May 5, 2020, the disclosures of which are incorporated herein by reference in their entireties. The components and configurations described below can be used in addition to or in place of the components and configurations described in these patent documents.

[0156] Figure 26 illustrates a first contact array (1700) including an array of electrical contacts (1702). By way of example only, electrical contacts (1702) may be provided in place of electrical contacts (924) (see Figure 15) and may further be configured to function similarly to electrical contacts (924), except as described below. As will be apparent to those skilled in the art in view of the teachings herein, electrical contacts (1702) may further be in electrical communication with control circuitry, a power source, and / or various other electrical features within handle assembly (910) (see Figure 15).

[0157] As shown, the contact array 1700 may be surrounded on at least one or both sides of the module connection by a grounded conductive shield 1706, which transmits any externally applied voltage to a return path, thereby preventing the externally applied voltage from reaching the contacts 1702 and any electronics connected to the contacts 1702. The shield 1706 is configured to receive a predetermined sealing pressure applied by features of the handle interface assembly 960 during mating, ensuring that the periphery of the contact array 1700 is protected and that no gaps develop in the shield 1706 due to interference or interaction between the contact array 1700 and the handle interface assembly 960. Thus, the shield 1706 is configured to divert voltage and current away from the contacts 1702 and also to seal the contact array 1700 from the intrusion of fluids that could otherwise interfere with the electrical connection or result in an electrical short. In an alternative configuration, rather than providing a shield (1706) around the contact array (1700), a conductive shield may be disposed around the entire module connection of the shaft, providing a means for the metal shaft component to have a lower resistance return path connection not only around the contact array (1700) but also around the module connection in general, thereby shielding the contacts (1702) from the metal frame.

[0158] In addition to the shield 1706, the contact array 1700 may also include one or more features 1704 disposed between adjacent contacts 1702. The features 1704 may be formed of a non-conductive material, such as an elastomer, and may be configured to prevent unwanted electrical bridges (i.e., shorts) from forming between two adjacent contacts 1702. More specifically, the features 1704 may provide space between the contacts 1702 and prevent electrical shorts even when the contact array 1700 is filled with fluid, such as by providing a minimum resistance level that is an order of magnitude greater than the inter-contact resistance during fluid contamination. In some variations, the features 1704 may each include an elastomeric wiper or be formed of a hydrophobic coating with high dielectric breakdown and resistivity, such as providing a resistance of 200 ohms or greater between the contacts 1702. The size and ratio of the features 1704 may be configured relative to the ratio and size of the contacts 1702, proportional to the current carrying capacity or resistance of the two contacts 1702, or proportional to the proximity of the features 1704 to the electrical return path and distance from the conductive shaft component. In some variations, each feature 1704 may be formed to have a different size relative to the other features 1704. In some variations, as described in more detail below, the features 1704 include active electronic controls or sensors 1708 for regulating the signal or power transmitted through one or more contacts 1702 by measuring the signal or power via the sensors 1708 and providing such measurements to a system console for continuous monitoring.

[0159] FIG. 27 illustrates an alternative contact array 1800 for providing substantially the same functionality as contact array 1700, except as described below. Contact array 1800 includes one or more features 1804 disposed between adjacent contacts 1802. Features 1804 may be formed of a non-conductive material, such as an elastomer, and may be configured to prevent unwanted electrical bridges (i.e., shorts) from forming between two adjacent contacts 1802. In some variations, features 1804 may each include an elastomeric wiper or may be formed of a hydrophobic coating with high dielectric breakdown and resistivity. Specifically, features 1804 may be configured with an upper seal or gasket 1806 extending over each contact 1802. Thus, each contact 1802 is configured to be completely enclosed when electrically connected to an end effector or other modular component, such that fluid cannot flow to or between any two contacts 1802. Nevertheless, the encapsulation provided by features 1804 may still allow the contacts 1802 to make proper electrical contact with corresponding contacts (not shown) in the handle interface assembly 960 of the shaft assembly 950 when the shaft assembly 950 is mated with the handle assembly 910. Although not shown, the encapsulation features 1804 and seal 1806 may further include a conductive shield disposed on an outer surface relative to the contacts 1802, which is configured to transmit voltage and current to ground, similar to the shield 1706 described above. In some variations, as described in more detail below, feature (1804) or seal (1806) includes an active electronic control or sensor (1808) for regulating the signal or power transmitted through one or more contacts (1802) by measuring the signal or power via sensor (1808) and providing such measurements to a system console for continuous monitoring.

[0160] FIG. 28 illustrates an alternative contact array 1900 for providing substantially the same functionality as the contact arrays 1700 and 1800, except as described below. Specifically, rather than including features disposed between or around the contacts 1902, the contacts 1902 may instead be appropriately spaced to prevent the formation of a voltage or bridge between the two contacts 1902. The ratio of the spacing 1904 between the contacts 1902 may be configured relative to the ratio and size of the contacts 1902 and the voltage configured to be transmitted across the contacts 1902. Alternatively, the ratio of the spacing 1904 between the contacts 1902 may be proportional to the current-carrying capacity or resistance of the two contacts 1902. Alternatively, the ratio of the spacing 1904 between the contacts 1902 may be, or may be proportional to, the proximity of the contacts 1902 to the electrical return path and their distance from the conductive shaft component. In some variations, as described in more detail below, the space (1904) includes an active electronic control or sensor (1906) for regulating the signal or power transmitted through one or more contacts (1902) by measuring the signal or power via the sensor (1906) and providing such measurements to a system console for continuous monitoring.

[0161] In addition to the above-described features for protecting the contact arrays (1700, 1800, 1900), signals on each contact array (1700, 1800, 1900) may also be actively measured by sensors (1708, 1808, 1906) during operation of the instrument to monitor for abnormal results, and signals indicative of the measurements may be transmitted to a console for monitoring. For example, if a voltage condition exceeding a predetermined threshold is detected, the console may take active measures to prevent damage and irregular voltage propagation to adjacent contacts. The console may receive voltage or current measurements from each conductive path or trace defined by the contact arrays (1700, 1800, 1900) and react accordingly to initiate corrective action. The console may be configured similarly to the console (20) described above with reference to FIG. 1 and may include a data processor configured and operable to initiate corrective action, such as adjusting the power profile transmitted to the end effector. Furthermore, the console may be a component of a robotic electrosurgical system, as described above. Various suitable forms that a console or other control module may take will be apparent to those skilled in the art in view of the teachings herein.

[0162] The console may be configured to take any of several corrective actions if abnormal voltages or currents are measured from the contact array (1700, 1800, 1900) or the shield (1706). For example, the console may be configured to automatically apply an active voltage clamp, adjust power output to the end effector, or take other similar protective action when electrical interference is detected. In some variations, the console may synchronize the voltage clamp with the activation signal for the instrument through a generator or hub interface. The console may also generate trend lines to adjust predicted error corrections and, in some cases, terminate RF power from the end effector if the console determines that a voltage or current threshold on the impedance array may be reached.

[0163] By utilizing the above-described features, the instrument may monitor the electrical potentials at various electrical contacts, slip joints, or other electrical interface components and adjust or compensate the power output to the end effector based on any detected losses. For example, the console may instruct the generator to increase or decrease the power output or apply one or more filters to the output signal. As described above, the signals on each contact array (1700, 1800, 1900) or shield (1706) may be actively monitored for abnormal electrical activity and active operational data provided to the console so that such decisions and adjustments can be made in real time.

[0164] X. Exemplary Combinations The following examples illustrate various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to limit the scope of the claims that may be presented at any time in this application or any subsequent application related to this application. No disclaimer is intended. The following examples are provided for illustrative purposes only. It is contemplated that the various teachings herein may be configured and applied in many other ways. It is also contemplated that certain features referred to in the following examples may be omitted in some variations. Accordingly, none of the aspects or features referred to below should be considered critical unless later expressly indicated as such by the inventors or their successors. If a claim presented in this application or any subsequent application related to this application includes additional features other than those referred to below, those additional features should not be considered added for any reasons of patentability. [Example]

[0165] 1. A method for performing an electrosurgical procedure, comprising: (a) applying an active electrode to a patient, the active electrode operably coupled to a conductive body of a surgical instrument; and (b) positioning a first ground electrode and a second ground electrode relative to the patient such that a first current path and a second current path are created in tissue of the patient, the first ground electrode including a first electrical lead coupled to an electrical ground node, the second ground electrode including a second electrical lead coupled to the electrical ground node, and the conductive body of the surgical instrument is operably coupled to the first ground electrode and the second ground electrode. (c) applying a first voltage to the active electrode to generate a therapeutic current in a first current path and a second current path, the current in the first current path and the second current path altering tissue of the patient; and (d) when a capacitive current is induced in a conductive body of the surgical instrument as a result of applying the first voltage to the active electrode, transmitting a first portion of the capacitive current from the conductive body to the first electrical lead and a second portion of the capacitive current from the conductive body to the second electrical lead. [Example]

[0166] 2. The method of example 1, wherein the first portion of the capacitive current is up to about 30% of the second portion of the capacitive current. [Example]

[0167] The method of any one or more of Examples 1-2, further comprising: (a) coupling the conductive body, the first electrical lead, and the second electrical lead together to form an electrical junction; and (b) electrically positioning a signal filter between the first electrical lead and the second electrical lead. [Example]

[0168] 4. The method of example 3, wherein the signal filter functions as a high-pass filter. [Example]

[0169] 5. The method of any one or more of Examples 3-4, further comprising applying a second voltage to the first ground electrode via the first electrical lead to generate a diagnostic current between the first ground electrode and the second ground electrode, wherein the signal filter prevents the diagnostic current from passing through the electrical junction. [Example]

[0170] The method according to Example 5, wherein the treatment current has a frequency of about 300 kHz to about 500 kHz, and the diagnostic current has a frequency of about 15 kHz to about 15 kHz. [Example]

[0171] 7. The method of any one or more of Examples 1-6, further comprising coupling the conductive body, the first electrical lead, and the second electrical lead with a transformer, the transformer operable to transmit a first portion of the capacitive current from the conductive body to the first electrical lead and to transmit a second portion of the capacitive current from the conductive body to the second electrical lead. [Example]

[0172] An electrosurgical system comprising: (a) an instrument including: (i) a body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue; and (iii) a conductive shield coupled to the body and including a ground return, the conductive shield configured to collect capacitively coupled currents induced by application of RF energy by the electrode; (b) a generator configured to supply RF energy to the electrode; and (c) a first ground pad having a first electrical lead, the first electrical lead being coupled to the first ground pad. and (d) a second grounding pad having a second electrical lead, the second electrical lead coupling the second grounding pad to the ground return of the conductive shield and the generator, the ground return configured to divert a second portion of the capacitively coupled current to the generator via the second electrical lead, the first and second portions of the capacitively coupled current being substantially equal. [Example]

[0173] The electrosurgical system of Example 8, wherein the RF energy has a frequency of about 300 kHz to about 500 kHz. [Example]

[0174] The electrosurgical system of any one or more of Examples 8-9, further comprising: (a) a conductive bridge configured to electrically couple the ground return, the first electrical lead, and the second electrical lead to one another; and (b) a signal filter electrically positioned between the first electrical lead and the second electrical lead. [Example]

[0175] 11. The electrosurgical system of example 10, wherein the signal filter comprises a high-pass filter. [Example]

[0176] An electrosurgical system as described in any one or more of Examples 10-11, wherein the generator is configured to provide a diagnostic signal to a first grounding pad via a first electrical lead, the second grounding pad is configured to return at least a portion of the diagnostic signal to the generator via a second electrical lead, and the signal filter is configured to prevent the diagnostic signal from passing through the conductive bridge. [Example]

[0177] 13. The electrosurgical system of claim 12, wherein the diagnostic signal has a frequency of about 15 kHz to about 50 kHz. [Example]

[0178] 14. The electrosurgical system of any one or more of Examples 8-13, further comprising a transformer configured to electrically couple between the ground return, the first electrical lead, and the second electrical lead, the transformer operable to transmit a first portion of the capacitively coupled current from the conductive shield to the first electrical lead and to transmit a second portion of the capacitively coupled current from the conductive shield to the second electrical lead. [Example]

[0179] An electrosurgical system according to any one or more of Examples 8 to 14, wherein the generator is configured to apply monopolar RF energy to the patient. [Example]

[0180] An electrosurgical system as described in any one or more of Examples 8 to 15, wherein the generator is configured to provide an AC diagnostic signal between the first grounding pad and the second grounding pad via the first electrical lead and the second electrical lead, and the other of the first grounding pad and the second grounding pad is configured to return at least a portion of the diagnostic signal to the generator. [Example]

[0181] An electrosurgical system comprising: (a) an instrument including: (i) a body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue; (ii) a conductive shield coupled to the body and including a ground return, the conductive shield configured to collect capacitively coupled currents induced by application of RF energy by the electrode; (b) a first grounding pad having a first electrical lead, the first electrical lead coupling the first grounding pad to a ground source; and (c) a second electrical lead. (d) a second grounding pad having a ground return of the conductive shield, the first electrical lead, and the second electrical lead, the second grounding pad having a ground return configured to divert a first portion of the capacitively coupled current to the ground source via the first electrical lead, and the ground return configured to divert a second portion of the capacitively coupled current to the ground source via the second electrical lead, the first and second portions of the capacitively coupled current being substantially equal. [Example]

[0182] 18. The electrosurgical system of example 17, wherein the conductive bridge includes a signal filter electrically positioned between the first electrical lead and the second electrical lead. [Example]

[0183] 19. The electrosurgical system of Example 18, further comprising a generator configured to provide RF energy, the generator configured to provide a diagnostic signal to a first grounding pad via a first electrical lead, the second grounding pad configured to return at least a portion of the diagnostic signal to the generator via a second electrical lead, and the signal filter preventing the diagnostic signal from passing through the conductive bridge. [Example]

[0184] 20. The electrosurgical system of any one or more of Examples 17-19, wherein the conductive bridge includes a transformer operable to transmit a first portion of the capacitively coupled current from the conductive shield to the first electrical lead and to transmit a second portion of the capacitively coupled current from the conductive shield to the second electrical lead. [Example]

[0185] A method for performing electrosurgical procedures using an instrument system, the instrument system including: (a) a surgical instrument having electrodes configured to operate on tissue of a patient; (b) a generator for powering the electrodes; and (c) one or more sensors configured to measure electrical energy flowing between the generator and the patient, the method comprising: (a) determining an electrical parameter threshold of capacitive coupling to monitor on conductive components of the surgical instrument during operation; (b) activating the electrodes of the surgical instrument by applying an output power signal from the generator to the electrodes, the output power signal having a first energy output profile; and (c) measuring an inductive coupling on the conductive components of the surgical instrument via the one or more sensors. (d) adjusting an output power signal of the generator from a first energy output profile to a second energy output profile when the induced electrical parameter measured from the conductive component of the surgical instrument meets or exceeds the electrical parameter threshold during operation, the adjustment being operable to reduce the induced electrical parameter measured from the conductive component of the surgical instrument, and the adjustment being further operable to reduce the parasitic energy loss without ceasing delivery of energy to the electrode. [Example]

[0186] 22. The method of example 21, wherein the conductive components of the surgical instrument are configured to avoid contact with the patient during operation, and the conductive components are separated from the electrodes. [Example]

[0187] 23. The method of any one or more of Examples 21-22, wherein a first sensor of the one or more sensors is configured to measure electrical energy transferred from the generator to the patient, and a second sensor of the one or more sensors is configured to measure electrical energy transferred from the patient to the generator, and the instrument system is configured to measure patient impedance between the first sensor and the second sensor, and the method further includes: (a) determining an impedance change threshold for monitoring during operation; (b) monitoring a change in patient impedance between the first sensor and the second sensor; and (c) adjusting the generator output power signal from the first energy output profile to the second energy output profile when the change in patient impedance during operation meets or exceeds the impedance change threshold. [Example]

[0188] 24. The method of any one or more of Examples 21-23, wherein adjusting the output power signal includes adjusting at least one of a voltage swing, a current limit, or a power limit. [Example]

[0189] 25. The method of any one or more of Examples 21-24, further comprising: (a) determining whether the generator reaches a power output regulation limit when adjusting the output power signal from the first energy output profile to the second energy output profile, thereby preventing the output power signal from being adjusted from the first energy output profile to the second energy output profile; and (b) disconnecting the output power signal from the electrodes if the generator has reached a power regulation limit. [Example]

[0190] The method of any one or more of Examples 21-25, wherein the conductive component of the surgical instrument comprises a metal shield. [Example]

[0191] 27. The method of any one or more of Examples 21-26, further comprising: (a) prior to activating the electrode of the surgical instrument, positioning a ground electrode on the patient to create a current pathway in the patient's tissue between the electrode and a ground electrode, the ground electrode comprising an electrical lead coupled to an electrical ground node. [Example]

[0192] The method of any one or more of Examples 21-27, wherein the generator is configured to apply monopolar RF energy to the patient. [Example]

[0193] The method of any one or more of Examples 21-28, wherein the surgical instrument is a handheld instrument. [Example]

[0194] The method of any one or more of Examples 21-29, wherein the surgical instrument is a component of a robotic electrosurgical system. [Example]

[0195] 31. The method of any one or more of Examples 21-30, wherein the appliance system further includes a tuner coupled to the generator, the tuner being selectively operable to adjust the output power signal of the generator, and wherein adjusting the output power signal of the generator from the first energy output profile to the second energy output profile includes (a) operating the tuner, thereby adjusting the output power signal of the generator from the first energy output profile to the second energy output profile. [Example]

[0196] The method of any one or more of Examples 21-31, wherein the electrical parameter threshold comprises a current threshold. [Example]

[0197] The method of any one or more of Examples 21-32, wherein the induced electrical parameter comprises an induced current. [Example]

[0198] 34. The method of any one or more of Examples 21-33, wherein the first energy output profile provides a first voltage and the second energy output profile provides a second voltage, the second voltage being less than the first voltage. [Example]

[0199] 35. The method of example 34, wherein the first energy output profile provides a first power level and the second energy output profile provides a second power level, the second power level being the same as the first power level. [Example]

[0200] An electrosurgical system comprising: (a) an instrument including: (i) a body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue of a patient; and (ii) a conductive component coupled to the body, the conductive component configured to collect capacitively coupled current induced by application of RF energy by the electrode; (b) a generator configured to supply RF energy to the electrode; and (c) a generator operably coupled to the generator and configured to: (i) generate a current on the conductive component during operation; an electrosurgical system comprising: (i) determining a capacitive coupling current threshold for monitoring; (ii) activating an electrode of the instrument by applying an output power signal from the generator to the electrode; (iii) monitoring induced current on conductive components of the instrument, the induced current including parasitic energy losses resulting from the electrode; and (iv) when the induced current meets or exceeds the current threshold during operation, adjusting the output power signal of the generator to reduce the induced current until it falls below the capacitive coupling current threshold while maintaining delivery of energy to the electrode. [Example]

[0201] An electrosurgical system as described in Example 36, further comprising a tuner coupled to the generator, wherein the controller is configured to selectively operate the tuner to adjust the output power signal of the generator. [Example]

[0202] An electrosurgical system described in any one or more of Examples 36 to 37, further comprising one or more sensors operably coupled to the controller and configured to measure capacitively coupled current and provide the current measurement values ​​to the controller. [Example]

[0203] An electrosurgical system as described in Example 38, wherein at least one of the one or more sensors is configured to measure an impedance value, and the controller is further configured to (i) determine an impedance change threshold for monitoring during operation, (ii) monitor changes in the impedance value, and (iii) adjust the output power signal of the generator when the change in the impedance value meets or exceeds the impedance change threshold during operation. [Example]

[0204] An electrosurgical system described in any one or more of Examples 36 to 39, wherein to adjust the output power signal, the controller is configured to adjust at least one of the voltage amplitude, the current limit, or the power limit. [Example]

[0205] 37. An electrosurgical system as described in Example 36, wherein the generator is configured to apply monopolar RF energy to the patient. [Example]

[0206] The electrosurgical system of Example 41, wherein the monopolar RF energy has a frequency of about 300 kHz to about 500 kHz. [Example]

[0207] 1. An electrosurgical system comprising: (a) an instrument including: (i) a body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue of a patient; and (ii) a conductive component coupled to the body, the conductive component configured to collect capacitively coupled current induced by application of RF energy by the electrode; (b) a generator configured to supply RF energy to the electrode sufficient to cut or seal tissue; (c) a sensor configured to measure the capacitively coupled current; and (d) a controller operatively coupled to the generator and the sensor and configured to: (i) determine a capacitive coupling current threshold to monitor on the conductive component during operation; (ii) monitor the induced current on the conductive component of the instrument; and (iii) when the induced current meets or exceeds the current threshold during operation, adjust the RF energy supplied by the generator to reduce the induced current until the induced current is below the capacitive coupling current threshold while maintaining delivery of energy to the electrode. [Example]

[0208] 1. A surgical system comprising: (a) a first instrument having a first end effector, the first end effector operable to apply a first type of energy to a patient's tissue; (b) a second instrument having a second end effector, the second end effector operable to apply a second type of energy to the patient's tissue; and (c) one or more generators configured to generate a first energy signal and a second energy signal, the one or more generators including: (i) a first generator output configured to transmit a first energy signal to the first end effector, the first energy signal operable to power the first end effector to apply the first type of energy to the patient's tissue; and (ii) a second energy signal. and (d) a power monitor operably coupled to the one or more generators, the power monitor configured to monitor a first energy parameter of the first energy signal and transmit the first energy parameter to the one or more generators, the one or more generators configured to adjust a second energy parameter of the second energy signal based at least in part on the transmitted first energy parameter to avoid interaction between the first energy signal and the second energy signal. [Example]

[0209] A surgical system as described in Example 44, wherein the one or more generators are configured to simultaneously generate a first energy signal and a second energy signal. [Example]

[0210] A surgical system described in any one or more of Examples 44-45, wherein the first energy parameter and the second energy parameter each include at least one of current, voltage, frequency, or waveform. [Example]

[0211] A surgical system described in any one or more of Examples 44 to 46, wherein the first end effector and the second end effector include at least one of a monopolar RF electrode, a bipolar RF electrode, or an ultrasonic blade. [Example]

[0212] A surgical system described in any one or more of Examples 44 to 47, further comprising one or more power sensors operably coupled to the power monitor, the one or more power sensors configured to measure a first energy parameter and transmit the measurement value to the power monitor. [Example]

[0213] A surgical system as described in Example 48, wherein the one or more power sensors include at least one of an RF power sensor or an ultrasonic transducer. [Example]

[0214] A surgical system described in any one or more of Examples 48-49, wherein the first instrument includes a monopolar RF instrument having a conductive component, the conductive component configured to collect capacitively coupled current induced by applying a first energy signal to the first end effector, and one or more power sensors configured to measure the capacitively coupled current and provide current measurements to the power monitor. [Example]

[0215] A surgical system as described in Example 50, wherein the power monitor is configured to transmit current measurements to one or more generators, and the one or more generators are configured to adjust a time constant parameter of the second energy signal. [Example]

[0216] The surgical instrument of any one or more of Examples 44-51, wherein the first instrument and the second instrument are each a handheld surgical instrument. [Example]

[0217] A surgical system described in any one or more of Examples 44 to 52, wherein the first instrument and the second instrument are each components of a robotic electrosurgical system. [Example]

[0218] A surgical system described in any one or more of Examples 44 to 53, wherein the one or more generators include a first generator and a second generator, the first generator output being part of the first generator and the second generator output being part of the second generator. [Example]

[0219] The surgical system of any one or more of Examples 44-54, wherein the first type of energy comprises electrosurgical energy. [Example]

[0220] 56. The surgical system of Example 55, wherein the first type of energy comprises monopolar RF electrosurgical energy and the second type of energy comprises bipolar RF electrosurgical energy. [Example]

[0221] A surgical system described in any one or more of Examples 55 to 56, further comprising a grounding pad configured to contact the patient's skin, the grounding pad further configured to couple to one or more generators, thereby providing a grounding return path. [Example]

[0222] A surgical system described in any one or more of Examples 44 to 57, wherein the second energy parameter includes a frequency-based energy parameter. [Example]

[0223] A surgical system comprising: (a) a first instrument having a first end effector operable to apply a first type of energy to tissue of a patient; (b) a second instrument having a second end effector operable to apply a second type of energy to tissue of a patient; and (c) a first generator configured to generate a first energy signal and transmit the first energy signal to the first end effector, the first energy signal operable to power the first end effector. (d) a second generator configured to generate and transmit a second energy signal to a second end effector, the second energy signal operable to power the second end effector; and (e) a power monitor operably coupled to the first generator, the power monitor configured to monitor the first energy signal of the first generator and transmit a corresponding measurement signal to the second generator, the second generator configured to adjust an energy parameter of the second energy signal in response to receiving the transmitted measurement signal. [Example]

[0224] 59. The surgical system of claim 59, wherein the second generator is configured to adjust energy parameters to distinguish energy parameters of the second energy signal from corresponding energy parameters of the first energy signal based at least in part on the transmitted measurement signal to avoid interaction between the first energy signal and the second energy signal. [Example]

[0225] A surgical system described in any one or more of Examples 59 to 60, wherein the power monitor is configured to monitor one or more of the current, voltage, frequency, or waveform of the first energy signal of the first generator, and the transmitted measurement signal is associated with the monitored one or more of the current, voltage, frequency, or waveform of the first energy signal. [Example]

[0226] A surgical system described in any one or more of Examples 59 to 61, wherein the first generator and the second generator are configured to simultaneously generate the first energy signal and the second energy signal. [Example]

[0227] A surgical system described in any one or more of Examples 59 to 62, wherein the first end effector and the second end effector each include at least one of a monopolar RF electrode, a bipolar RF electrode, or an ultrasonic blade. [Example]

[0228] A surgical system described in any one or more of Examples 59 to 63, further comprising one or more sensors operably coupled to the power monitor, the one or more sensors configured to measure one or more corresponding energy parameters of the first energy signal of the first generator. [Example]

[0229] A surgical system as described in Example 64, wherein the one or more sensors include at least one of an RF power sensor or an ultrasonic transducer. [Example]

[0230] A surgical system described in any one or more of Examples 59 to 65, wherein the first instrument includes a monopolar RF instrument having a conductive component, the conductive component configured to collect capacitively coupled current induced by applying a first energy signal to the first end effector, and the system further comprises one or more sensors configured to measure the capacitively coupled current and provide current measurements to a power monitor. [Example]

[0231] 67. A surgical system as described in Example 66, wherein the power monitor is configured to transmit the current measurement value to the second generator, and the second generator is configured to adjust a time constant parameter of the second energy signal. [Example]

[0232] 1. A method for performing an electrosurgical procedure, the method comprising: (a) generating a first energy signal having a first frequency for powering a first end effector of a surgical instrument, the first end effector applying a first type of energy to tissue of a patient; (b) generating a second energy signal having a second frequency for simultaneously powering a second end effector of the surgical instrument, the second end effector applying the second type of energy to tissue of the patient; (c) measuring the first frequency of the first energy signal; and (d) adjusting a second frequency of the second energy signal based on the measured frequency of the first energy signal to prevent the second energy signal from interacting with the first energy signal, thereby distinguishing the second frequency from the first frequency. [Example]

[0233] 1. A surgical instrument comprising: (a) a shaft assembly having a plurality of conductive components; (b) an end effector positioned at a distal end of the shaft assembly, the end effector operable to apply energy to tissue of a patient; (c) a console operable to supply power to the end effector; (d) a conductor assembly disposed within the shaft assembly and configured to transfer power from the console to the end effector, the conductor assembly including a ground return path; and (e) a plurality of voltage sensors, each of the plurality of conductive components configured to couple to a corresponding one of the plurality of voltage sensors and to the ground return path, the plurality of voltage sensors operable to measure a voltage potential difference of the coupled conductive component relative to a ground potential defined by the ground return path; wherein the console is configured to (i) determine whether the measured voltage potential difference exceeds a maximum threshold value; and (ii) initiate corrective action when the measured voltage potential difference exceeds the maximum threshold value. [Example]

[0234] 69. The surgical instrument of claim 69, wherein each conductive component of the plurality of conductive components is configured with a floating voltage. [Example]

[0235] A surgical instrument described in any one or more of Examples 69-70, wherein the shaft assembly or end effector further includes a motion sensor operable to sense a parameter associated with the motion of the end effector, and the corrective action includes adjusting an electrical noise correction threshold associated with the motion sensor. [Example]

[0236] A surgical instrument described in any one or more of Examples 69 to 71, wherein the shaft assembly or end effector further includes a motion sensor operable to sense a parameter associated with the motion of the end effector, and the corrective action includes adjusting a voltage conversion associated with the motion sensor. [Example]

[0237] A surgical instrument described in any one or more of Examples 69 to 72, wherein the shaft assembly or end effector further includes a motion sensor operable to sense a parameter associated with the motion of the end effector, and the corrective action includes ignoring a signal from the motion sensor. [Example]

[0238] A surgical instrument described in any one or more of Examples 69 to 73, wherein the shaft assembly or end effector further includes an operation sensor operable to sense a parameter associated with operation of the end effector, and the corrective action includes cutting off power to the operation sensor. [Example]

[0239] A surgical instrument described in any one or more of Examples 69 to 74, wherein the shaft assembly or end effector further includes an operation sensor operable to sense a parameter associated with operation of the end effector, and the corrective action includes restarting the operation sensor. [Example]

[0240] A surgical instrument described in any one or more of Examples 69 to 75, wherein the corrective action includes discharging selected conductive components of the plurality of conductive components to a ground return path. [Example]

[0241] 77. The surgical instrument of embodiment 76, wherein the corrective action further includes ceasing sensing from a voltage sensor associated with the selected conductive component while the voltage is being discharged. [Example]

[0242] A surgical instrument described in any one or more of Examples 69 to 77, wherein each of the plurality of conductive components is configurable to be electrically interconnected, and each of the plurality of conductive components shares a common voltage potential when electrically interconnected. [Example]

[0243] 79. The surgical instrument of Example 78, wherein the console is operable to reduce a common voltage potential from the plurality of conductive components relative to ground potential while the plurality of conductive components are electrically interconnected. [Example]

[0244] A surgical instrument described in any one or more of Examples 69 to 79, wherein the plurality of voltage sensors includes high impedance voltage sensors. [Example]

[0245] A surgical instrument described in any one or more of Examples 69 to 80, wherein the console includes a generator configured to provide RF energy to the end effector. [Example]

[0246] The surgical instrument of any one or more of Examples 69-81, wherein the conductor assembly comprises a wiring harness. [Example]

[0247] A surgical instrument described in any one or more of Examples 69 to 82, wherein the console is a component of a robotic electrosurgical system. [Example]

[0248] 1. A surgical instrument comprising: (a) a shaft assembly having a plurality of conductive components, each conductive component of the plurality of conductive components configured with a floating voltage; (b) an end effector positioned at a distal end of the shaft assembly, the end effector operable to apply energy to tissue of a patient; (c) a console operable to supply power to the end effector; (d) a conductor assembly disposed within the shaft assembly and configured to transfer power from the console to the end effector, the conductor assembly including a ground return path; and (e) a plurality of voltage sensors, each conductive component of the plurality of conductive components configured to couple to a corresponding voltage sensor of the plurality of voltage sensors and to the ground return path, the plurality of voltage sensors operable to measure a voltage difference of the coupled conductive component relative to a ground potential defined by the ground return; and the console configured to initiate corrective action based on the measured voltage potential difference. [Example]

[0249] The surgical instrument of Example 84, further comprising a motion sensor operable to sense a parameter associated with the motion of the end effector, and the corrective action includes adjusting an electrical noise correction threshold associated with the motion sensor. [Example]

[0250] A surgical instrument described in any one or more of Examples 84-85, further comprising a motion sensor operable to sense a parameter associated with the motion of the end effector, and the corrective action includes adjusting a voltage conversion associated with the motion sensor. [Example]

[0251] A surgical instrument described in any one or more of Examples 84 to 86, wherein each of the plurality of conductive components is configurable to be electrically interconnected, and the corrective action includes electrically interconnecting the plurality of conductive components, and each of the plurality of conductive components shares a common voltage potential when electrically interconnected. [Example]

[0252] 1. A surgical instrument comprising: (a) a shaft assembly having a conductive component configured with a floating voltage; (b) an end effector positioned at a distal end of the shaft assembly, the end effector operable to apply energy to tissue of a patient; (c) a console operable to supply power to the end effector; (d) a conductor assembly disposed within the shaft assembly and configured to transfer power from the console to the end effector, the conductive assembly including a ground return path; and (e) a voltage sensor, the conductive component of the shaft assembly configured to couple to the voltage sensor and to couple to the ground return path, the voltage sensor operable to measure a voltage potential difference of the conductive component relative to a ground potential defined by the ground return; wherein the console is configured to (i) determine whether the measured voltage potential difference exceeds a maximum threshold value; and (ii) initiate corrective action when the measured voltage potential difference exceeds the maximum threshold value. [Example]

[0253] An apparatus comprising: (a) a shaft assembly including: (i) a first shaft component; (ii) a second shaft component; (iii) a joint connecting the first shaft component to the second shaft component, the second shaft component being movable relative to the first shaft component at the joint; and (iv) a sliding electrical coupling at the joint, the sliding electrical coupling configured to provide electrical communication between the first shaft component and the second shaft component while allowing movement of the second shaft component relative to the first shaft component at the joint; and (b) an end cap positioned at a distal end of the shaft assembly. 1. An apparatus comprising: (a) an end effector, the end effector operable to engage tissue of a patient; (c) a control module operable to supply power to the end effector; and (d) a first sensor positioned adjacent to the joint, the first sensor configured to (i) measure a joint parameter indicative of a condition of the sliding electrical coupling and (ii) transmit a first signal indicative of the measured joint parameter to the control module, the control module configured to (i) determine whether the measured joint parameter exceeds a maximum deviation from a predetermined value; and (ii) initiate a first response action when the measured joint parameter exceeds the maximum deviation from the predetermined value. [Example]

[0254] 89. The device of claim 89, wherein the shaft assembly defines a longitudinal axis and the second shaft component is rotatable about the longitudinal axis relative to the first shaft component at the joint. [Example]

[0255] An apparatus described in any one or more of Examples 89 to 90, wherein the first response action includes increasing the power signal provided to the end effector by the control module. [Example]

[0256] An apparatus described in any one or more of Examples 89 to 91, wherein the first response action includes reducing the power signal provided to the end effector by the control module. [Example]

[0257] An apparatus described in any one or more of Examples 89 to 92, further comprising a second sensor operable to (i) measure a first operating parameter associated with operation of the end effector and (ii) transmit a second signal indicative of the measured first operating parameter to the control module, the control module being configured to execute a control algorithm based at least in part on the second signal. [Example]

[0258] 94. The apparatus of embodiment 93, wherein the first response measure includes adjusting a signal processing magnitude of a second signal transmitted by a second sensor while executing the control algorithm. [Example]

[0259] An apparatus described in any one or more of Examples 93-94, further comprising a third sensor operable to (i) measure a second operating parameter associated with operation of the end effector and (ii) transmit a third signal indicative of the measured second operating parameter to the control module, and the first response action includes complementing the second signal with the third signal while executing the control algorithm. [Example]

[0260] An apparatus described in any one or more of Examples 93-94, further comprising a third sensor operable to (i) measure a second operating parameter associated with operation of the end effector and (ii) transmit a third signal to the control module indicative of the measured second operating parameter, and the first response action includes replacing the second signal with the third signal while executing the control algorithm. [Example]

[0261] An apparatus described in any one or more of Examples 89 to 94, further comprising a third sensor operable to (i) measure a second operating parameter associated with operation of the end effector and (ii) transmit a third signal indicative of the measured second operating parameter to the control module, the control module being configured to ignore the third signal while executing the control algorithm if the measured joint parameter does not exceed a maximum deviation from a predetermined value. [Example]

[0262] The apparatus of any one or more of Examples 89-97, wherein the joint parameter indicates the electrical resistance of the sliding electrical joint. [Example]

[0263] 99. The apparatus of Example 98, wherein the predetermined value is an electrical resistance value associated with a predetermined maximum temperature value. [Example]

[0264] 99. The apparatus of any one or more of Examples 89-99, wherein the joint parameter indicates a voltage at a sliding electrical coupling. [Example]

[0265] 101. The apparatus of any one or more of Examples 89-100, wherein the joint parameter indicates a temperature of the sliding electrical joint. [Example]

[0266] An apparatus described in any one or more of Examples 89 to 101, further comprising an orientation sensor configured to sense a change in orientation in the joint, and wherein the control module is configured to correlate the change in orientation sensed by the orientation sensor with measured joint parameters and determine whether to initiate an alternative operating mode. [Example]

[0267] The apparatus of example 102, wherein an alternative operating mode includes configuring the control module to vary power to the end effector based on a change in orientation at the joint. [Example]

[0268] An apparatus described in any one or more of Examples 89 to 103, wherein the first response action includes adjusting a maximum power limit of the end effector. [Example]

[0269] A device described in any one or more of Examples 89 to 104, wherein the end effector is operable to apply RF energy to tissue. [Example]

[0270] An apparatus described in any one or more of Examples 89 to 105, wherein the control module is a component of a robotic electrosurgical system. [Example]

[0271] An apparatus comprising: (a) a shaft assembly including: (i) a first shaft component; (ii) a second shaft component, the first and second shaft components together defining a longitudinal axis; (iii) a rotary joint connecting the first shaft component to the second shaft component, the second shaft component being rotatable about the longitudinal axis relative to the first shaft component at the rotary joint; and (iv) a sliding electrical coupling at the rotary joint, the sliding electrical coupling configured to provide electrical communication between the first and second shaft components while permitting rotation of the second shaft component relative to the first shaft component at the rotary joint; (b) an end effector positioned at a distal end of the shaft assembly, the end effector operable to engage tissue of a patient; (c) a control module operable to supply power to the end effector; and (d) a sensor positioned adjacent to the rotary joint, the sensor configured to (i) measure a joint parameter indicative of one or more of an electrical resistance of the sliding electrical coupling, a voltage of the sliding electrical coupling, or a temperature of the sliding electrical coupling, and (ii) send a signal indicative of the measured joint parameter to the control module, wherein the control module is configured to (i) determine whether the measured joint parameter exceeds a maximum deviation from a predetermined value, and (ii) initiate a response action when the measured joint parameter exceeds a maximum deviation from a predetermined value. [Example]

[0272] 1. A method of operating a surgical instrument, the surgical instrument including: a shaft assembly having a first shaft component and a second shaft component coupled to one another by a joint; an end effector positioned at a distal end of the shaft assembly; a control module operable to supply power to the end effector; and a sensor positioned adjacent to the joint, the method including: (a) providing a power signal from the control module to the end effector; (b) measuring, by the sensor, an electrical parameter or a thermal parameter at the joint; (c) sending a signal indicative of the measured electrical parameter or thermal parameter to the control module; (d) determining, by the control module, whether the electrical parameter or thermal parameter exceeds a maximum deviation from a predetermined electrical parameter value or a thermal parameter value; and (e) adjusting the power signal provided from the control module to the end effector when the electrical parameter or thermal parameter exceeds the maximum deviation from the predetermined electrical parameter value or a thermal parameter value. [Example]

[0273] 1. A device comprising: (a) a shaft assembly; (b) an end effector positioned at a distal end of the shaft assembly, the end effector operable to engage tissue of a patient; (c) a control module configured to generate an electrical power output to supply power to the end effector; (d) a first electrical connector operably coupled to the control module, the first electrical connector including a first plurality of electrical contacts, at least one electrical contact of the first plurality of electrical contacts configured to transmit the electrical power output to a second plurality of electrical contacts of the second electrical connector while the first electrical connector and the second electrical connector are coupled; and (e) a plurality of non-conductive structures disposed adjacent each of the plurality of first electrical contacts, the plurality of non-conductive structures configured to prevent signal interference between each electrical contact of the first plurality of electrical contacts. [Example]

[0274] An apparatus as described in Example 109, wherein each of the multiple non-conductive structures includes a sensor, and each sensor is configured to measure an electrical signal of an adjacent electrical contact. [Example]

[0275] An apparatus as described in Example 110, wherein the sensor is configured to transmit a measurement value of the electrical signal to the control module. [Example]

[0276] The apparatus of example 3, wherein the control module is configured to (i) determine whether the electrical signal exceeds a voltage threshold or a current threshold, and (ii) initiate corrective action when the electrical signal exceeds the voltage threshold or the current threshold. [Example]

[0277] The device of example 112, wherein the corrective action includes adjusting the power output. [Example]

[0278] A device described in any one or more of Examples 109 to 5, wherein each non-conductive structure of the plurality of non-conductive structures is disposed between two electrical contacts of the first plurality of electrical contacts. [Example]

[0279] A device described in any one or more of Examples 109 to 114, wherein each non-conductive structure of the plurality of non-conductive structures is sized proportionally based on the proximity of the non-conductive structure between two corresponding electrical contacts of the first plurality of electrical contacts. [Example]

[0280] An apparatus described in any one or more of Examples 109 to 115, wherein each non-conductive structure of the plurality of non-conductive structures is proportionally sized based on the proximity of the non-conductive structure to electrical ground as defined by the power output and the proximity of the non-conductive structure to conductive components of the shaft assembly. [Example]

[0281] The device of Example 116, wherein two of the plurality of non-conductive structures have different sizes from each other. [Example]

[0282] 118. The device of any one or more of Examples 109-117, wherein each non-conductive structure of the plurality of non-conductive structures is proportionally sized based on the current carrying capacity of two adjacent electrical contacts of the first plurality of electrical contacts. [Example]

[0283] The device of any one or more of Examples 109-118, wherein each non-conductive structure of the plurality of non-conductive structures is sized proportionally based on the electrical resistance between two adjacent electrical contacts of the first plurality of electrical contacts. [Example]

[0284] A device described in any one or more of Examples 109 to 119, wherein each non-conductive structure of the plurality of non-conductive structures provides a resistance of greater than 200 ohms between two adjacent electrical contacts of the first plurality of electrical contacts. [Example]

[0285] A device described in any one or more of Examples 109 to 120, wherein the plurality of non-conductive structures are configured to encapsulate respective electrical contacts of the first plurality of electrical contacts to form a liquid-tight seal. [Example]

[0286] A device described in any one or more of Examples 109 to 121, wherein the end effector is operable to receive and apply monopolar RF energy sufficient to cut or seal tissue. [Example]

[0287] An apparatus described in any one or more of Examples 109 to 122, wherein the control module is a component of a robotic electrosurgical system. [Example]

[0288] 1. A surgical instrument comprising: (a) a shaft assembly; (b) an end effector positioned at a distal end of the shaft assembly, the end effector operable to apply energy to tissue of a patient; (c) a first electrical connector configured to couple with a control module, the first electrical connector including a first plurality of electrical contacts; (d) a second electrical connector having a second plurality of electrical contacts configured to mate with the first plurality of electrical contacts to form a plurality of conductive bridges, at least one electrical contact of the first plurality of electrical contacts configured to transmit an electrical power signal to at least one corresponding electrical contact of the second plurality of electrical contacts while the first electrical connector and the second electrical connector are coupled; and (e) a plurality of non-conductive structures disposed adjacent to respective electrical bridges of the plurality of electrical bridges, the plurality of non-conductive structures configured to prevent interference of electrical power signals between the first plurality of electrical bridges. [Example]

[0289] The device described in Example 124, further comprising a body, wherein the shaft assembly is configured to be removably coupled to the body, the first electrical connector being incorporated into the body, and the second electrical connector being incorporated into the shaft assembly. [Example]

[0290] The device of any one or more of Examples 124-125, further comprising a conductive shield surrounding the first plurality of electrical contacts, the conductive shield being coupled to ground. [Example]

[0291] The device of Example 126, wherein the conductive shield is further configured to provide a fluid-tight seal around the first plurality of electrical contacts and the second plurality of electrical contacts while the first electrical connector and the second electrical connector are coupled. [Example]

[0292] 1. A surgical instrument comprising: (a) a shaft assembly; (b) an end effector positioned at a distal end of the shaft assembly, the end effector operable to engage tissue of a patient; (c) a first electrical connector including a first plurality of electrical contacts; and (d) a second electrical connector having a second plurality of electrical contacts configured to mate with the first plurality of electrical contacts to form a plurality of conductive bridges, at least one electrical contact of the first plurality of electrical contacts configured to transmit a power signal to at least one electrical contact of the second plurality of electrical contacts while the first electrical connector and the second electrical connector are coupled, wherein each of the plurality of conductive bridges is spaced apart by a distance, the distance being proportionally sized based on the current carrying capacity of two adjacent conductive bridges to prevent signal interference between the two adjacent conductive bridges of the plurality of conductive bridges.

[0293] XI. Other Variations of the above described devices can be applied not only to traditional medical procedures and surgeries performed by medical professionals, but also to robotic-assisted medical procedures and surgeries.

[0294] It should be understood that any of the variations of the devices described herein may include various other features in addition to or in place of those described above. By way of example only, any of the devices described herein may further include one or more of the various features disclosed in any of the various references incorporated by reference herein. It should also be understood that the teachings herein may be readily applied to any of the devices described in any of the other references cited herein, and thus the teachings herein may be readily combined in many ways with the teachings of any of the references cited herein. Other types of devices into which the teachings herein may be incorporated will be readily apparent to those skilled in the art.

[0295] In addition to the above, the teachings herein may be readily combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP2.0735556], filed on even date herewith, entitled "Electrosurgical Instrument System with Parasitic Energy Loss Monitor," the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein may be combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP2.0735556] will be apparent to those skilled in the art in view of the teachings herein.

[0296] In addition to the above, the teachings herein may be readily combined with the teachings of commonly assigned U.S. Patent Application No. [Attorney Docket No. END9294USNP3.0735558] entitled "Energized Surgical Instrument System with Multi-Generator Output Monitoring," the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein may be combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP3.0735558] will be apparent to those skilled in the art in light of the teachings herein.

[0297] In addition to the above, the teachings herein may be readily combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP4.0735564], entitled "Electrosurgical Instrument with Shaft Voltage Monitor," filed on even date herewith, the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein may be combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP4.0735564] will be apparent to those skilled in the art in view of the teachings herein.

[0298] In addition to the above, the teachings herein may be readily combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP5.0735566], filed on even date herewith, entitled "Electrosurgical Instrument with Electrical Resistance Monitor at Rotary Coupling," the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein may be combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP5.0735566] will be apparent to those skilled in the art in view of the teachings herein.

[0299] In addition to the above, the teachings herein may be readily combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP6.0735568], entitled "Electrosurgical Instrument with Modular Component Contact Monitoring," filed on even date herewith, the disclosure of which is incorporated herein by reference. Various suitable ways in which the teachings herein may be combined with the teachings of U.S. Patent Application No. [Attorney Docket No. END9294USNP6.0735568] will be apparent to those skilled in the art in view of the teachings herein.

[0300] It should also be understood that any range of values ​​recited herein should be read to include the limits of such range. For example, a range expressed as "about 1.0 inch to about 1.5 inches" should be read to include about 1.0 inch and about 1.5 inches, in addition to including values ​​between those limits.

[0301] It should be understood that all or part of any patent, publication, or other disclosure referred to herein as being incorporated by reference is incorporated herein only to the extent that the incorporated material does not contradict existing definitions, opinions, or other disclosures set forth in this disclosure. As such, and to the extent necessary, the disclosures explicitly set forth herein shall supersede any conflicting statements incorporated herein by reference. Any material, or portions thereof, that is referred to herein as being incorporated by reference but that contradicts current definitions, opinions, or other disclosures set forth herein shall be incorporated only to the extent that no conflict arises between the incorporated material and the current disclosures.

[0302] The above-described variations may be designed to be disposed of after a single use, or they may be designed to be used multiple times. In either or both cases, the variations can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular parts, and subsequent reassembly. In particular, some device variations can be disassembled and any number of particular parts or components of the device can be selectively replaced or removed in any combination. Upon cleaning and / or replacement of particular parts, some device variations may be reassembled for subsequent use either at a reconditioning facility or by an operator immediately prior to a procedure. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning / replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

[0303] By way of example only, the variations described herein may be sterilized before and / or after treatment. In one sterilization technique, the device is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and device may then be placed in a radiation field that can penetrate the container, such as gamma radiation, x-rays, or a high-energy electron beam. The radiation may kill bacteria on the device and in the container. The sterilized device may then be stored in the sterile container for later use. The device may also be sterilized using any other technique known in the art, including, but not limited to, beta or gamma radiation, ethylene oxide, or steam.

[0304] While various embodiments of the present invention have been shown and described, further adaptations of the methods and systems described herein may be realized by those skilled in the art through appropriate modifications without departing from the scope of the present invention. While some such possible modifications have been described, other modifications will be apparent to those skilled in the art. For example, the examples, embodiments, geometries, materials, dimensions, proportions, steps, etc. discussed above are illustrative and not required. Accordingly, it will be understood that the scope of the present invention should be considered in terms of the claims that follow, and is not limited to the details of construction and operation shown and described in the specification and drawings.

[0305] [Embodiment] (1) A method for performing an electrosurgical procedure, comprising: (a) applying an active electrode to a patient, the active electrode being operably coupled to a conductive body of a surgical instrument; (b) positioning a first ground electrode and a second ground electrode relative to the patient such that a first current path and a second current path are respectively defined between the active electrode and the first and second ground electrodes in tissue of the patient, the first ground electrode including a first electrical lead coupled to an electrical ground node, the second ground electrode including a second electrical lead coupled to the electrical ground node, and the conductive body of the surgical instrument being coupled to the first and second electrical leads of the first and second ground electrodes, respectively; (c) applying a first voltage to the active electrode to generate a therapeutic current in the first current path and the second current path, the current in the first current path and the second current path altering tissue of the patient; (d) when a capacitive current is induced in the conductive body of the surgical instrument as a result of applying the first voltage to the active electrode, transmitting a first portion of the capacitive current from the conductive body to the first electrical lead and transmitting a second portion of the capacitive current from the conductive body to the second electrical lead. (2) The method of embodiment 1, wherein the first portion of the capacitive current is up to about 30% of the second portion of the capacitive current. (3) (a) bonding the conductive body, the first electrical lead, and the second electrical lead together to form an electrical junction; 2. The method of claim 1, further comprising: (b) electrically positioning a signal filter between the first electrical lead and the second electrical lead. (4) The method of embodiment 3, wherein the signal filter functions as a high-pass filter. (5) The method of embodiment 3, further comprising applying a second voltage to the first ground electrode via the first electrical lead to generate a diagnostic current between the first ground electrode and the second ground electrode, wherein the signal filter prevents the diagnostic current from passing through the electrical junction.

[0306] (6) The method according to embodiment 5, wherein the therapeutic current has a frequency of about 300 kHz to about 500 kHz, and the diagnostic current has a frequency of about 15 kHz to about 50 kHz. (7) The method of embodiment 1, further comprising coupling the conductive body, the first electrical lead, and the second electrical lead to a transformer, the transformer operable to transfer the first portion of the capacitive current from the conductive body to the first electrical lead and to transfer the second portion of the capacitive current from the conductive body to the second electrical lead. (8) An electrosurgical system comprising: (a) An appliance, (i) a main body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue; (iii) a conductive shield coupled to the body and including a ground return, the conductive shield configured to collect capacitively coupled currents induced by the application of the RF energy by the electrodes; (b) a generator configured to supply the RF energy to the electrode; (c) a first ground pad having a first electrical lead coupling the first ground pad to the ground return of the conductive shield and to the generator, the ground return configured to divert a first portion of the capacitively coupled current to the generator via the first electrical lead; (d) a second grounding pad having a second electrical lead, the second electrical lead coupling the second grounding pad to the ground return of the conductive shield and to the generator, the ground return configured to divert a second portion of the capacitively coupled current to the generator via the second electrical lead, and the first and second portions of the capacitively coupled current are substantially equal. (9) An electrosurgical system according to embodiment 8, wherein the RF energy has a frequency of about 300 kHz to about 500 kHz. (10) (a) a conductive bridge configured to electrically couple the ground return, the first electrical lead, and the second electrical lead to one another; 9. The electrosurgical system of claim 8, further comprising: (b) a signal filter electrically positioned between the first electrical lead and the second electrical lead.

[0307] (11) An electrosurgical system as described in embodiment 10, wherein the signal filter includes a high-pass filter. (12) The electrosurgical system of claim 10, wherein the generator is configured to provide a diagnostic signal to the first grounding pad via the first electrical lead, the second grounding pad is configured to return at least a portion of the diagnostic signal to the generator via the second electrical lead, and the signal filter is configured to prevent the diagnostic signal from passing through the conductive bridge. (13) An electrosurgical system according to claim 12, wherein the diagnostic signal has a frequency of about 15 kHz to about 50 kHz. (14) The electrosurgical system of embodiment 8, further comprising a transformer configured to electrically couple between the ground return, the first electrical lead, and the second electrical lead, the transformer operable to transfer the first portion of the capacitively coupled current from the conductive shield to the first electrical lead and to transfer the second portion of the capacitively coupled current from the conductive shield to the second electrical lead. (15) An electrosurgical system as described in embodiment 8, wherein the generator is configured to apply monopolar RF energy to the patient.

[0308] (16) The electrosurgical system of embodiment 8, wherein the generator is configured to provide an AC diagnostic signal between the first grounding pad and the second grounding pad via the first electrical lead and the second electrical lead, and the other of the first grounding pad and the second grounding pad is configured to return at least a portion of the diagnostic signal to the generator. (17) An electrosurgical system comprising: (a) An appliance, (i) a main body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue; (ii) a conductive shield coupled to the body and including a ground return, the conductive shield configured to collect capacitively coupled currents induced by the application of the RF energy by the electrodes; (b) a first ground pad having a first electrical lead, the first electrical lead coupling the first ground pad to a ground source; (c) a second ground pad having a second electrical lead, the second electrical lead coupling the second ground pad to the ground source; and (d) a conductive bridge configured to electrically couple the ground return of the conductive shield, the first electrical lead, and the second electrical lead to one another, wherein the ground return is configured to divert a first portion of the capacitively coupled current to the ground source via the first electrical lead and the ground return is configured to divert a second portion of the capacitively coupled current to the ground source via the second electrical lead, wherein the first and second portions of the capacitively coupled current are substantially equal. (18) The electrosurgical system according to embodiment 17, wherein the conductive bridge includes a signal filter electrically positioned between the first electrical lead and the second electrical lead. (19) The electrosurgical system of claim 18, further comprising a generator configured to provide the RF energy, the generator configured to provide a diagnostic signal to the first grounding pad via the first electrical lead, the second grounding pad configured to return at least a portion of the diagnostic signal to the generator via the second electrical lead, and the signal filter preventing the diagnostic signal from passing through the conductive bridge. (20) The electrosurgical system of embodiment 17, wherein the conductive bridge includes a transformer operable to transmit the first portion of the capacitively coupled current from the conductive shield to the first electrical lead and to transmit the second portion of the capacitively coupled current from the conductive shield to the second electrical lead.

Claims

1. 1. An electrosurgical system comprising: (a) An apparatus comprising: (i) a main body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue; (iii) a conductive shield coupled to the body and including a ground return, the conductive shield configured to collect capacitively coupled currents induced by the application of the RF energy by the electrodes; (b) a generator configured to supply the RF energy to the electrode; (c) a first ground pad having a first electrical lead coupling the first ground pad to the ground return of the conductive shield and to the generator, the ground return configured to divert a first portion of the capacitively coupled current to the generator via the first electrical lead; (d) a second grounding pad having a second electrical lead coupling the second grounding pad to the ground return of the conductive shield and to the generator, the ground return configured to divert a second portion of the capacitively coupled current to the generator via the second electrical lead, and wherein the first and second portions of the capacitively coupled current are substantially equal.

2. The electrosurgical system according to claim 1 , wherein the RF energy has a frequency of about 300 kHz to about 500 kHz.

3. (a) a conductive bridge configured to electrically couple the ground return, the first electrical lead, and the second electrical lead to one another; The electrosurgical system according to claim 1, further comprising: (b) a signal filter electrically positioned between the first electrical lead and the second electrical lead.

4. The electrosurgical system according to claim 3 , wherein the signal filter includes a high-pass filter.

5. 4. The electrosurgical system according to claim 3, wherein the generator is configured to provide a diagnostic signal to the first grounding pad via the first electrical lead, the second grounding pad is configured to return at least a portion of the diagnostic signal to the generator via the second electrical lead, and the signal filter is configured to prevent the diagnostic signal from passing through the conductive bridge.

6. The electrosurgical system according to claim 5, wherein the diagnostic signal has a frequency of about 15 kHz to about 50 kHz.

7. 2. The electrosurgical system according to claim 1, further comprising a transformer configured to electrically couple between the ground return, the first electrical lead, and the second electrical lead, the transformer operable to transfer the first portion of the capacitively coupled current from the conductive shield to the first electrical lead and to transfer the second portion of the capacitively coupled current from the conductive shield to the second electrical lead.

8. The electrosurgical system of claim 1 , wherein the generator is configured to apply monopolar RF energy to a patient.

9. 2. The electrosurgical system according to claim 1, wherein the generator is configured to provide an AC diagnostic signal between the first and second grounding pads via the first and second electrical leads, the other of the first and second grounding pads being configured to return at least a portion of the AC diagnostic signal to the generator.

10. 1. An electrosurgical system comprising: (a) An apparatus comprising: (i) a main body; (ii) an end effector coupled to a distal end of the body, the end effector including an electrode operable to apply RF energy to tissue; (iii) a conductive shield coupled to the body and including a ground return, the conductive shield configured to collect capacitively coupled currents induced by the application of the RF energy by the electrodes; (b) a first ground pad having a first electrical lead, the first electrical lead coupling the first ground pad to a ground source; (c) a second ground pad having a second electrical lead, the second electrical lead coupling the second ground pad to the ground source; and (d) a conductive bridge configured to electrically couple the ground return of the conductive shield, the first electrical lead, and the second electrical lead to one another, the ground return configured to divert a first portion of the capacitively coupled current to the ground source via the first electrical lead, and the ground return configured to divert a second portion of the capacitively coupled current to the ground source via the second electrical lead, the first and second portions of the capacitively coupled current being substantially equal.

11. The electrosurgical system according to claim 10, wherein the conductive bridge includes a signal filter electrically positioned between the first electrical lead and the second electrical lead.

12. 12. The electrosurgical system according to claim 11, further comprising a generator configured to provide the RF energy, the generator configured to provide a diagnostic signal to the first grounding pad via the first electrical lead, the second grounding pad configured to return at least a portion of the diagnostic signal to the generator via the second electrical lead, and the signal filter preventing the diagnostic signal from passing through the conductive bridge.

13. The electrosurgical system according to claim 10, wherein the conductive bridge includes a transformer operable to transfer the first portion of the capacitively coupled current from the conductive shield to the first electrical lead and to transfer the second portion of the capacitively coupled current from the conductive shield to the second electrical lead.

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