Hand-Held Surgical Modules With Dual-Output Planetary Gearboxes

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Solution Overview

Problem

Existing electromechanical surgical instruments face challenges in efficiently powering diverse surgical end effectors with varying power and speed requirements using a single reusable handle assembly.

Innovation Solution

A surgical instrument module with a dual-output gearbox that includes a high-torque, low-speed output and a high-speed, low-torque output, driven by a motor, allowing simultaneous operation of different surgical end effectors through a single planetary gear system, accommodating discrete power and speed needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a single motor drives different surgical end effectors with varying power and speed requirements, then versatility is improved, but device complexity increases due to the need for a dual-output gearbox with multiple planetary gear assemblies

Engineering Contradiction:

Improveability to power multiple surgical end effectorsVSAvoidgearbox structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The motor assembly is designed with a dual-output gearbox that simultaneously provides high-torque output and high-speed output, enabling a single motor to power multiple types of surgical end effectors with different operational requirements. This multi-functionality allows one reusable handle assembly to accommodate various surgical instruments without requiring separate motor assemblies for each instrument type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The gearbox is divided into multiple independent planetary gear assemblies (first, second, third, and fourth planetary gear assemblies), each responsible for generating a specific output type. This segmentation allows the complex dual-output function to be achieved through modular, manageable components that can be independently designed and assembled.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If high-torque and high-speed outputs are provided simultaneously, then operational versatility is improved, but the size and weight of the motor assembly increase

Engineering Contradiction:

Improvesimultaneous operation capabilitiesVSAvoidmotor assembly weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The planetary gear assemblies are arranged in a nested configuration where the second and fourth planetary gear assemblies are positioned within the structural envelope defined by the first and third planetary gear assemblies. This nesting approach allows the dual-output gearbox to achieve compact packaging of multiple gear trains, reducing the overall size and weight of the motor assembly while maintaining both high-torque and high-speed output capabilities.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20250268595A1Hand-held surgical instruments

Publication Date: 2025.08.28 COVIDIEN LP

AI summary

A surgical instrument module for powering a plurality of discrete surgical end effectors includes a motor, a planetary gear box, a high-torque/low-speed output operably coupled to the motor, and a high-speed/low-torque output operably coupled to the motor. The high-torque/low-speed output is configured to be operably coupled to a driven member of a first type of surgical end effector, and the high-speed/low-torque output is configured to drive an operation of a second type of surgical end effector.