Replaceable Torque Limiter Coupling Unit for Surgical Instruments
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Solution Overview
Problem
Existing torque limiters in surgical instruments suffer from decreasing torque accuracy over time, leading to a limited lifespan and significant waste and costs, as they require recalibration or disposal after reaching a maximum lifetime or sterilization cycles.
Innovation Solution
A torque limiter design featuring a replaceable coupling unit that can be swapped without specialized tools, allowing for extended instrument life by maintaining torque accuracy through adjustable torque limits and minimizing wear on critical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a torque limiter is used in surgical instruments with fixed or adjustable torque limits, then torque control is achieved, but the torque accuracy decreases with time leading to limited instrument lifetime
Solution Approach 1:
The torque limiter is divided into two separable parts: a reusable housing and a replaceable coupling unit. The coupling unit contains the torque-limiting mechanism and can be replaced after a defined lifetime or when torque accuracy deteriorates, while the housing remains in use. This segmentation allows the critical torque-limiting component to be renewed without replacing the entire instrument.
Solution Approach 2:
The coupling unit is designed as a disposable or replaceable component that can be discarded after reaching its maximum lifetime or when torque accuracy is no longer acceptable. The reusable housing recovers and continues to serve, reducing waste of the expensive overall instrument system while ensuring torque accuracy is maintained through replacement of the worn coupling unit.
2Measurement precision
If the entire torque limiter or surgical instrument is replaced after reaching maximum lifetime, then torque accuracy is guaranteed, but instrument waste and costs increase significantly
Solution Approach 1:
The torque limiter is segmented into a reusable housing and a replaceable coupling unit. Only the coupling unit needs to be replaced when torque accuracy deteriorates or lifetime is reached, rather than replacing the entire instrument. This reduces material waste significantly while maintaining torque accuracy through the use of a new, calibrated coupling unit.
Solution Approach 2:
The coupling unit is designed to be discarded or replaced after a defined lifetime, while the housing is recovered and reused. This approach minimizes instrument waste by keeping the durable housing in service indefinitely, replacing only the consumable coupling unit that contains the torque-limiting mechanism.
3Ease of operation
If the coupling unit is made replaceable without specialized tools, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The torque limiter is segmented into a housing and a coupling unit with a standardized interface. The interface is designed to be simple and tool-free, allowing the coupling unit to be easily removed and replaced by the user. This segmentation enables easy replacement while keeping the overall device structure relatively simple through modular design.
Solution Approach 2:
The coupling unit interface is designed as a universal, standardized connection that can be easily engaged and disengaged without specialized tools. This universal design simplifies the replacement operation while the modular structure maintains acceptable device complexity by using standard mechanical interfaces.
Data Source
AI summary
A torque limiter, especially for a surgical instrument, with an axis of rotation includes an input element for the input of torque into the torque limiter, an output element for the output of torque from the torque limiter and a coupling unit having a coupling body by means of which the input element can be coupled with the output element. The coupling unit is arranged in the torque limiter so that it can be replaced. The preferred invention also includes handle unit with a torque limiter and a surgical instrument with a torque limiter.