Adjustable Surgical Handpiece Coupling Assembly
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Solution Overview
Problem
Current surgical tool systems lack flexibility in positioning cutting accessories relative to the handpiece, requiring multiple accessories with different shaft lengths to accommodate varying surgical needs, and unused sterilized accessories are often discarded due to discoloration during sterilization, leading to resource waste.
Innovation Solution
The surgical tool system allows for adjustable positioning of cutting accessories via a coupling assembly that enables both coarse and fine adjustments of the accessory shaft's extension/retraction by serial engagement of locking elements with retention features, and the use of tool steel which, despite discoloration, remains sterile and usable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed coupling assembly is used to secure cutting accessories, then the accessory can be securely held in one position, but the surgeon cannot adjust the accessory position to accommodate different surgical sites or personal preferences
Solution Approach 1:
The coupling assembly is designed with movable locking elements that can transition between locked and unlocked states, enabling dynamic adjustment of accessory position. The spring-loaded locking elements allow the accessory to be positioned at multiple locations along the drive shaft and secured at each position, providing adaptability without requiring a completely complex mechanism.
Solution Approach 2:
The coupling assembly is divided into discrete components including locking elements, retention features, and spring mechanisms. This segmentation allows each component to perform a specific function while working together to achieve adjustable positioning. The modular design enables the complex function of adjustable securing to be achieved through simpler, standardized parts.
2Adaptability or versatility
If multiple cutting accessories with different shaft lengths are provided to accommodate varying surgical needs, then positioning flexibility is achieved, but the quantity of accessories increases and resource waste occurs when sterilized accessories are discarded due to discoloration
Solution Approach 1:
A single cutting accessory can serve multiple positioning functions by being adjustable to different locations along the drive shaft. The accessory with retention features can engage with locking elements at multiple positions, allowing one accessory to replace what would traditionally require multiple accessories of different lengths. This universal design reduces the total number of accessories needed in the system.
Solution Approach 2:
The effective length and position of the accessory relative to the handpiece are changed by adjusting the engagement position of the locking elements along the drive shaft. This parameter adjustment allows a single accessory to provide the functional equivalent of multiple accessories with different fixed lengths, eliminating the need to discard sterilized accessories due to discoloration when different positioning is needed.
3Reliability
If tool steel accessories are sterilized, then sterility is achieved, but discoloration occurs during sterilization leading to perceived quality degradation and disposal of still-sterile accessories
Solution Approach 1:
The material composition of the accessory is changed from traditional stainless steel to tool steel, which has different physical and chemical properties. Tool steel is more resistant to discoloration during sterilization processes while maintaining sterility. This parameter change in material composition allows the accessory to withstand sterilization without the harmful discoloration effect, maintaining both reliability and perceived quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system provides flexible accessory positioning without the need for multiple accessories and reduces waste by ensuring sterilized tool steel accessories remain usable post-sterilization, maintaining their quality and sterility.
Implementation Method 1
The motor includes a rotor having plural magnets disposed within a bore of the rotor, and a stator having windings disposed about the rotor. The windings can be self-supporting windings. The rotor and stator are disposed such that energizing the windings imparts motion to the rotor.
Data Source
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AI summary
A powered surgical handpiece includes a housing, an electric motor disposed in the housing, the motor including plural windings, and a rotor having a longitudinal axis and an even number of magnets. The rotor is disposed within the windings. The powered surgical handpiece further includes an output drive shaft connected to the motor rotor to be rotated by the motor rotor, the output drive shaft having an elongated bore dimensioned to receive the shaft of a cutting accessory. Furthermore, the powered surgical handpiece includes a coupling assembly with at least one locking element that extends into the bore of the output drive shaft, the at least one locking element releasably holding the cutting accessory shaft to the output drive shaft so that the cutting accessory shaft rotates in unison with the output drive shaft. The rotor is formed with an axially extending bore and the magnets are disposed in the rotor bore, wherein each said magnet has an outer surface located adjacent the bore-defining inner surface of said rotor, and two side surfaces that extend away from the outer surface and towards the longitudinal axis of said motor rotor so as to define a corner between the inner side surfaces that is located adjacent the longitudinal axis of the rotor and spaced inwardly from the magnet outer surface. The magnets are arranged so that a first pole of a said magnet is located at the outer surface of the magnet and the opposed second pole is located at the corner of the magnet and said magnets are disposed in the rotor bore so that arcuately adjacent magnets have corners with opposed magnetic polarities.