Powered Stapler Manual Override for Rack Retraction Failure
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Solution Overview
Problem
Powered surgical stapling devices face difficulties when power is lost or components malfunction, leading to the device becoming clamped on tissue and preventing removal from a patient.
Innovation Solution
A surgical device with a powered handle assembly that includes a motor assembly, toothed rack, gear shaft, spur gear, and bevel gear, allowing for manual override through a retraction tool to facilitate manual retraction of the toothed rack, enabling the device to be manually operated when power is lost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a powered stapling device is used to reduce operating force, then ease of operation is improved, but reliability deteriorates when power is lost or components malfunction
Solution Approach 1:
The device includes a manual retraction mechanism with a retraction tool and gear system that is prepared in advance within the handle assembly. This preliminary mechanical structure allows the operator to manually retract the drive beam and remove the device from the patient even when power is lost or the motor assembly fails, thus resolving the reliability issue while maintaining ease of operation during normal powered use
2Device complexity
If the device is designed with only powered actuation, then device complexity is reduced, but adaptability deteriorates when power loss occurs
Solution Approach 1:
The handle assembly is designed with multi-functionality by integrating both the motor assembly for powered actuation and the manual retraction mechanism with gear system. This allows the single device to adapt to different operational scenarios: normal powered operation when functional, and manual retraction when power is lost or components fail, thereby improving adaptability without significantly increasing overall device complexity
3Reliability
If a manual retraction mechanism is added to the powered device, then reliability is improved, but device complexity increases
Solution Approach 1:
The manual retraction mechanism is nested within the existing handle assembly structure. The retraction tool, gear system, and associated components are integrated into the cavity of the handle housing, with the gear shaft and spur gear positioned within the existing spatial framework. This nesting approach allows the manual retraction mechanism to be added while minimizing the increase in overall device complexity and maintaining a compact design
Data Source
AI summary
A surgical device (10) includes a powered handle assembly (12) that is coupled to a tool assembly (16) by an elongate body (14). The powered handle assembly (12) includes a motor assembly (46) that is coupled to a toothed rack (48) by a gear assembly (51). The motor assembly (46) can be actuated to advance or retract the toothed rack (48) to actuate the tool assembly (16). The handle assembly (12) includes a housing (18) that defines an opening (84) that is dimensioned to receive a retraction tool (90) that is configured to engage the gear assembly (51) and manually override the motor assembly (46) to facilitate manual retraction of the toothed rack (48).