Calibrated Motor Assembly for Surgical Clamping Force Control

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Solution Overview

Problem

Existing surgical instruments, such as staplers and vessel sealers, face challenges in controlling the force at the distal tip, leading to improper clamping and sealing due to manufacturing variances and wear, resulting in inadequate staple formation and tissue damage.

Innovation Solution

A calibrated motor assembly with integrated memory and electronics for motor control, including initial and final calibration, torque limit setting, and data storage to ensure precise clamping force and torque management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If standard manufacturing processes are used for surgical instruments, then production efficiency is maintained, but manufacturing precision deteriorates due to variances affecting clamping force consistency

Engineering Contradiction:

Improveclamping force consistencyVSAvoidinstrument calibration system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent implements preliminary calibration of motors during manufacturing to establish baseline torque parameters before the instrument reaches the surgeon. This preliminary action compensates for manufacturing variances in motor assembly, ensuring consistent clamping force across all instruments without requiring complex real-time control systems during surgery.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system measures and records actual torque parameters for each motor during calibration, then uses these measured parameter values to adjust control settings. This parameter-based approach transforms each instrument's unique characteristics into optimized performance, resolving manufacturing precision issues through data-driven customization.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If high clamping force is applied to ensure proper staple formation, then staple quality improves, but tissue damage increases due to excessive force

Engineering Contradiction:

Improvestaple formation accuracyVSAvoidtissue damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates torque sensors that provide real-time feedback on the force being applied during clamping. This feedback mechanism allows the control system to monitor and adjust clamping force dynamically, ensuring sufficient force for proper staple formation while preventing excessive force that would damage tissue. The system continuously compares actual torque against target values and makes corrections as needed.

Inventive Principle:

Principle #23Feedback

3Reliability

If motor torque is increased to compensate for wear over time, then clamping force is maintained, but the risk of tissue damage increases

Engineering Contradiction:

Improveclamping force stabilityVSAvoidtissue damage risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system performs self-calibration and self-adjustment through automated torque measurement and parameter storage. Rather than requiring manual intervention or increasing torque universally, the instrument monitors its own performance characteristics and adjusts control parameters accordingly. This self-service approach maintains reliable clamping force while adapting to wear patterns without risking tissue damage through brute-force torque increases.

Inventive Principle:

Principle #25Self-service

4Manufacturing precision

If manual calibration procedures are used for each instrument, then manufacturing precision improves, but productivity decreases due to time-consuming calibration

Engineering Contradiction:

Improvetorque parameter accuracyVSAvoidinstrument assembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical calibration procedures with automated electronic measurement and control systems. Torque parameters are measured automatically using electronic sensors and recorded in memory, eliminating the need for time-consuming manual adjustment and testing. This automation maintains high manufacturing precision while dramatically increasing assembly and calibration throughput.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250262012A1Motor assembly

Publication Date: 2025.08.21 INTUITIVE SURGICAL OPERATIONS INC

AI summary

Techniques for controlling an instrument using a motor assembly include a control system having a first memory storing instructions and a processor. When the processor executes the instructions, the processor is configured to receive one or more motor parameters stored in a second memory of the motor assembly, receive one or more instrument parameters stored in a third memory of an instrument, determine an instruction for a motor of the motor assembly based on at least the one or more motor parameters and the one or more instrument parameters, and transmit the instruction to the motor assembly. The motor assembly is coupled to the control system. The instrument is coupled to the motor assembly. The instruction is for controlling motion of an end effector of the instrument using the motor.