Circular Stapler Motor Control via Force Feedback
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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 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 automation and productivity are improved, but control and tactile feedback are reduced
Solution Approach 1:
The patent implements feedback mechanisms including force sensors that detect tissue resistance and provide real-time feedback to the control system. This allows the motorized device to adjust its operation based on actual tissue conditions, maintaining surgical control while preserving the benefits of automation. The force feedback enables the surgeon to sense tissue characteristics and operation progress despite the electrically-powered nature of the device.
2Productivity
If motor power is increased to perform cutting and sealing functions, then productivity is improved, but risk of motor stall and device damage increases
Solution Approach 1:
The patent employs preliminary detection of tissue properties using force sensors before the motor engages full power for cutting or sealing. This allows the control system to pre-adjust motor parameters and prepare for varying tissue conditions, preventing motor stalls before they occur. The system proactively monitors load conditions and adjusts power delivery to match actual tissue resistance, ensuring reliable operation at high power levels.
Solution Approach 2:
The control system dynamically adjusts motor power delivery based on real-time feedback from force sensors. Rather than operating at fixed high power, the system modulates motor output to match actual tissue conditions, maintaining sufficient power for cutting and sealing while avoiding excessive force that could cause motor stalls or tissue damage. This dynamic adaptation ensures both productivity and reliability.
3Device complexity
If a single actuation button controls multiple functions, then device complexity is reduced, but precision and control over individual functions deteriorate
Solution Approach 1:
The patent segments the control of different functions (cutting, sealing, stapling) into independently controllable parameters within the control system. While a single actuation button initiates the overall procedure, the control system independently manages each function's timing, power level, and duration based on sensor feedback. This allows precise control over each surgical function while maintaining a relatively simple user interface.
4Productivity
If the knife is driven through tissue with high force to ensure complete cutting, then cutting effectiveness is improved, but risk of device damage and patient harm increases
Solution Approach 1:
The patent uses force sensors to continuously monitor the resistance encountered during knife advancement through tissue. The control system adjusts motor power in real-time based on this feedback, applying sufficient force to ensure complete cutting while immediately reducing power when the cut is complete or when excessive resistance is detected. This prevents both incomplete cuts and excessive force application that could damage the device or harm the patient.
Solution Approach 2:
The knife drive system operates dynamically with continuously adjustable power levels rather than fixed high-force operation. The control system modulates motor output to match the actual cutting resistance, ensuring effective cutting through tough tissue while automatically reducing force when the cut progresses or when the knife exits the tissue. This dynamic control eliminates the need for consistently high force, reducing damage risk while maintaining cutting effectiveness.
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.