High Speed Drill One-Stage Power Train for Surgical Burr

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Solution Overview

Problem

Conventional high speed drills used in surgical procedures experience overheating and rapid vibrations due to high torques, leading to inefficient operation and potential tissue damage, and employ inefficient two-stage power train assemblies that result in energy losses and reduced longevity.

Innovation Solution

A high speed drill design featuring a one-stage power train assembly with direct torque transfer from a motor shaft to a burr shank via a motor shaft extension and a universal joint for angled cutting burrs, along with a clutch for switching between straight and angled cutting tips, and ball connectors to limit axial motion, reducing heat generation and vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional two-stage power train assemblies are used, then power can be transmitted from motor to burr, but energy losses occur and overheating results

Engineering Contradiction:

Improveenergy lossesVSAvoidoverheating

Core Design Contradiction:

Loss of energyVSTemperature

Solution Approach 1:

The patent removes the intermediate drive shaft and gear-to-gear power train from the conventional two-stage system, extracting only the essential power transmission function. The motor shaft directly engages the burr shank through a simplified one-stage power train, eliminating unnecessary components that cause energy losses and overheating.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a universal joint as an intermediary mechanism that enables direct coupling between the motor shaft and burr shank. This universal joint allows for angular misalignment while maintaining efficient power transmission, reducing energy losses compared to conventional gear systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Speed

If high speed drills operate at 85,000 rpm, then cutting performance is achieved, but high torques cause overheating and breakdown

Engineering Contradiction:

Improverotations per minuteVSAvoidbreakdown risk

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent replaces the complex multi-stage mechanical power train with a simplified direct-drive system. The motor shaft extension directly engages the burr shank, eliminating intermediate gears and drive shafts that are prone to breakdown under high torque conditions at 85,000 rpm.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If conventional gear-to-gear power train is used, then power transmission is achieved, but rapid vibrations and chattering occur

Engineering Contradiction:

Improvepower transmissionVSAvoidvibrations

Core Design Contradiction:

PowerVSStability of the object's composition

Solution Approach 1:

The patent removes the gear-to-gear power train entirely, extracting only the essential function of transmitting rotational motion from the motor to the burr. This eliminates the gear meshing that causes rapid vibrations and chattering during operation.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The universal joint introduces dynamic flexibility to the power transmission system, allowing for angular movement and reducing rigid mechanical constraints that cause vibrations. This dynamic coupling smooths power transmission without the chattering associated with rigid gear connections.

Inventive Principle:

Principle #15Dynamics

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

The design minimizes overheating, extends the device's service life, and enhances power transmission efficiency, reducing vibrations and noise, while allowing for precise surgical procedures with reduced collateral tissue damage.

Implementation Method 1

a universal joint for transferring rotational motion from a drive shaft to a burr shank

Methodology Applied

Scientific EffectUniversal joint mechanism:

Implementation Method 2

a two ball mechanism for locking axial movement of a burr shank

Methodology Applied

Scientific EffectMechanical constraint:

Implementation Method 3

a mechanism for transferring torque directly to a burr shank via an extension of a burr shank mechanically linked to a motor shaft

Methodology Applied

Scientific EffectTorque transfer: Torque

Data Source

PatentUS10806466B2High speed drill configured with multiple cutting burr attachments

Publication Date: 2020.10.20 GYRUS ACMI INC

AI summary

Systems and methods for a high speed drill cutting burr are described. The high speed drill may comprise a main body having a first section and a second section, the first section comprising a first housing configured to be operably connectable to a first cutting tip and the second section comprising a second housing configured to be operably connectable to a second cutting tip, and an electrical motor disposed inside the main body, the electrical motor may be configured to be in electrical communication with a power source. In some embodiments, a main body may be repositioned by rotating the main body 180° to switch between use of a first cutting tip and a second cutting tip. Mechanisms for limiting axial movement of a burr shank as well as transferring torque are described.