Motorized Controller Module for External Fixation Strut Adjustment
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Solution Overview
Problem
Existing external fixation systems face challenges in ease and precision of strut adjustment, particularly in achieving precise and controlled adjustments for bone deformity correction, with potential user errors in manual adjustments.
Innovation Solution
The system incorporates adjustable length struts with manual and automated modes of operation, allowing for discrete or infinitesimal length adjustments, respectively, using a controller module with a motor and gear mechanism for precise strut length control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual actuation is used for strut adjustment, then ease of operation is improved, but manufacturing precision deteriorates due to discrete length increments and potential user errors
Solution Approach 1:
The system dynamically switches between manual and automated modes based on operational needs. The actuator can operate in manual mode for ease of use or engage with the controller module for automated precise adjustment, making the system adaptable to different precision requirements throughout the correction process
Solution Approach 2:
The controller module acts as an intermediary between the user and the strut adjustment mechanism. It receives input signals and translates them into precise motor-driven adjustments, eliminating direct manual manipulation errors while maintaining user control and oversight
2Manufacturing precision
If automated actuation with controller module is used, then manufacturing precision is improved through infinitesimal length adjustments, but device complexity worsens
Solution Approach 1:
The actuator is designed with multi-functionality, capable of operating in both manual and automated modes. This universal design allows the same hardware component to serve different purposes, reducing the need for separate systems and thereby limiting the increase in device complexity
Solution Approach 2:
The controller module autonomously manages the motorized adjustment process, self-regulating the strut length based on programmed parameters without requiring constant user intervention. This self-service capability simplifies the user interface while maintaining high precision
3Reliability
If automated mode with controller module is coupled to strut, then reliability is improved through precise control, but ease of operation deteriorates due to system coupling requirements
Solution Approach 1:
The system allows dynamic switching between manual and automated modes, enabling users to choose the most appropriate operation mode based on the specific task requirements, thus maintaining ease of operation while ensuring reliability when needed
4Ease of operation
If discrete length increments are used in manual mode, then ease of operation is improved, but measurement precision worsens
Solution Approach 1:
The controller module serves as an intermediary that translates user intent into precise motor-driven adjustments. It can execute infinitesimal length changes beyond discrete increments, providing high measurement precision while still being controllable through simple interface inputs
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
Enables precise and stable strut length adjustments, reducing user error and enhancing the accuracy of bone deformity correction, with the ability to switch between manual and automated modes for flexibility and reliability.
Implementation Method 1
Each controller module may include a motor configured to rotate the controller gear
Implementation Method 2
an actuator configured to drive the rod axially relative to the tube to change an effective length of the strut
Data Source
AI summary
An external fixation system may include first and second fixation rings and a plurality of adjustable length struts. Each adjustable length strut may have two joints, a rod, a tube, and an actuator configured to drive the rod axially relative to the tube to change an effective length of the strut. The system may include a plurality of controller modules each configured to couple to a corresponding strut. The external fixation system may have a manual mode of operation in which the controller modules are not coupled to the struts, and manual actuation of the actuators changes the effective lengths of the struts in discrete length increments. The external fixation system may have an automated mode of operation in which the controller modules are coupled to the struts, and automated actuation of the actuators changes the effective lengths of the struts in infinitesimally small length increments.