Circular Stapler Control System Motor Stall Detection
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Solution Overview
Problem
Electrically-powered surgical devices lack control and tactile feedback, leading to reduced situational awareness for surgeons, potential device and patient damage due to motor stalls, and less precise operations compared to manually-operated devices.
Innovation Solution
A surgical stapling system with a control system that independently actuates inner and outer circular rows of staples and a knife, providing real-time feedback through displacement, force, and velocity monitoring to ensure precise tissue stapling and cutting, and includes a hand-held or robotic system configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an electrically-powered surgical device is used, then productivity and precision are improved, but loss of information and reliability deteriorate due to lack of tactile feedback and motor stall detection
Solution Approach 1:
The patent implements a feedback mechanism where the control system receives real-time data from sensors monitoring motor current, velocity, and position. This feedback loop enables the system to detect motor stalls and tissue characteristics, providing the surgeon with situational awareness equivalent to tactile feedback through electronic monitoring and alert systems.
2Force
If motor power is increased to ensure adequate cutting and sealing force, then force capability is improved, but object-generated harmful factors worsen due to potential tissue damage during motor stall
Solution Approach 1:
The control system is configured to monitor motor parameters in real-time and detect stall conditions before they cause tissue damage. When a stall is detected through abnormal current or velocity patterns, the system automatically reduces motor power or reverses direction, preventing the high forces that would otherwise cause tissue injury during prolonged stalling.
3Device complexity
If a single motor drives multiple functions, then device complexity is reduced, but reliability worsens due to inability to independently control stapling and cutting
Solution Approach 1:
The patent divides the drive system into separate motor assemblies for stapling and cutting functions. Each motor can be independently controlled by the control system, allowing precise timing and force control for each function. This segmentation enables reliable independent actuation while maintaining overall system coordination through centralized control.
Data Source
AI summary
Systems and methods for stapling tissue, a vessel, duct, etc., during a surgical procedure are provided. The surgical stapling systems generally include a circular stapling tool with a shaft extending therefrom that has an end effector at a distal end thereof. The end effector can have a staple deck and an anvil. The circular stapling tool can be configured to drive at least two circular rows of staples through tissue engaged between the staple deck and the anvil to thereby staple the tissue, and the tool can be configured to drive a knife through tissue engaged between the staple deck and the anvil to thereby cut the tissue. The surgical stapling system can also include a control system that is configured to communicate with the circular stapling tool.