Segmented Surgical Stapling System with Modular Adapter Assembly
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Solution Overview
Problem
Existing electromechanical surgical devices are costly to manufacture and operate, and their complex power transmission mechanisms can lead to unintended operation, potentially causing damage or injury due to inadvertent actuation, necessitating a need for more affordable and safe surgical apparatus with effective electromechanical transmission systems and safety lockout assemblies.
Innovation Solution
A surgical stapling system featuring a hand-held instrument with a battery, motor, and computer components, along with a removable and replaceable adapter assembly, and a reload system including a staple cartridge assembly and anvil assembly, where the adapter assembly has a flexible bar mechanism and articulation links to securely attach and operate the reload units, and a sled assembly with a knife mechanism for precise tissue handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex electromechanical linkages are used to transmit power from handle assemblies to disposable loading units, then the surgical devices can achieve desired operational functions (rotation, pivoting, clamping, fastener ejection), but the complexity of the power transmission mechanisms increases the risk of inadvertent actuation and unintended operation
Solution Approach 1:
The surgical system is divided into separate reusable handle assemblies and disposable loading units, with the power transmission mechanism segmented into modular components including drive shafts, gears, and linkages that can be independently analyzed and controlled. This segmentation allows for focused safety features at critical interfaces.
Solution Approach 2:
Electromechanical linkages act as intermediary components between the motor in the handle assembly and the surgical tools in the loading unit. These linkages include drive shafts, gears, and mechanical connectors that transmit power while providing controlled engagement and disengagement points to prevent unintended operation.
2Adaptability or versatility
If expensive electromechanical surgical devices with complex power transmission mechanisms are manufactured, then desired surgical functions can be achieved, but the manufacturing and operational costs increase
Solution Approach 1:
The system separates expensive reusable components (handle assemblies with motors and control systems) from disposable loading units, allowing the expensive parts to be manufactured once and reused. This reduces overall manufacturing costs compared to fully disposable or fully custom systems.
Solution Approach 2:
The handle assembly is designed as a universal platform that can interface with multiple types of loading units and surgical tools through standardized mechanical and electrical connections. This multi-functionality reduces manufacturing costs by avoiding the need for separate specialized devices for each surgical function.
3Productivity
If reusable handle assemblies with motors are used to power disposable loading units, then operational efficiency is improved, but the complexity of the electromechanical transmission system increases the potential for unintended operation
Solution Approach 1:
The power source (motor) and control system are extracted into the reusable handle assembly, separate from the disposable loading units. This extraction allows the loading units to be simpler in design while maintaining operational efficiency through the powered connection to the handle assembly.
Solution Approach 2:
Manual mechanical operation is replaced with an electromechanical system where motors in the handle assembly provide powered actuation of surgical tools. This substitution improves operational efficiency by reducing manual effort while the modular design manages the associated complexity.
Data Source
AI summary
A surgical device includes a jaw assembly, an articulating assembly and a drive shaft. The jaw assembly includes first and second jaws. The articulating assembly is removably coupled to a proximal end of the jaw assembly and includes a distal joint member, a proximal joint member, and a pivot pin. The pivot pin is fixedly coupled to the distal joint member and is rotatably coupled to the proximal joint member. The jaw assembly and the distal joint member together define a first longitudinal axis. The proximal joint member defines a second longitudinal axis. The drive shaft includes a gear element that is meshingly engaged with a pivoting gear element that is fixedly coupled to the pivot pin. Longitudinal movement of the first drive shaft pivots the jaw assembly relative to the proximal joint member about a pivot axis defined by the pivot pin.