Self-Aligning Drive Coupler for Surgical Handpiece Assembly
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Solution Overview
Problem
Current surgical instruments face misalignment issues during assembly with handpieces, requiring manual intervention for proper rotational engagement, which can lead to incomplete coupling and difficulty in cleaning due to inaccessible geometry.
Innovation Solution
A self-aligning drive coupler system with a drive hub and coupler featuring radial lobes that rotate upon axial insertion to ensure correct alignment, utilizing materials like stainless steel, aluminum, and polymers to facilitate easy assembly and cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention is used to align drive hub and drive coupler, then assembly can be completed, but assembly time increases and complexity increases
Solution Approach 1:
The drive coupler automatically aligns itself with the drive hub through the self-aligning lobe mechanism during telescoping insertion, eliminating the need for manual intervention. The lobe's geometry causes automatic rotational alignment as the components are pushed together, making the assembly process self-completing without requiring operator rotation or adjustment.
Solution Approach 2:
The lobe is pre-configured with specific geometric angles and dimensions that predetermine the alignment path during assembly. The preliminary design of the lobe geometry ensures that when telescoping force is applied, the components automatically rotate to the correct orientation before final engagement, preparing the alignment in advance rather than requiring manual adjustment during assembly.
2Manufacturing precision
If manual rotation is required for engagement, then proper alignment can be achieved, but device complexity increases
Solution Approach 1:
The lobe features an asymmetric cross-sectional geometry with different dimensions in radial and axial directions. This asymmetric shape creates a mechanical advantage where the lobe must follow a specific rotational path during insertion, automatically guiding alignment without requiring manual rotation. The asymmetric profile ensures precise angular positioning through geometric constraints rather than complex mechanisms.
Solution Approach 2:
The assembly mechanism transitions from a static alignment requirement to a dynamic self-aligning process. During telescoping insertion, the lobe dynamically rotates relative to the drive hub, converting linear insertion motion into rotational alignment motion. This dynamic behavior automatically achieves precise alignment through the interaction forces between the lobe and hub during the assembly process itself.
3Reliability
If complex geometry is used for coupling, then secure engagement is achieved, but cleaning accessibility worsens
Solution Approach 1:
The coupling interface is segmented into distinct functional elements: the lobe with its specific geometry for engagement, the drive hub reception features, and clearances between components. This segmentation allows the complex coupling function to be achieved through simple, cleanable geometric features rather than intricate interlocking mechanisms. The separated functional zones maintain coupling security while minimizing crevices that would hinder cleaning.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
Systems and methods herein are associated with a handpiece, a drive hub, a drive coupler, and an instrument comprising an elongate shaft and resection member telescoped within the elongate shaft, the resection member coupled to the drive hub. The drive hub comprises an interior surface and an exterior surface, the interior surface defines a cross- sectional shape, and the drive hub is coupled to a drive shaft of a motor of the handpiece. The drive coupler comprises a first lobe extending radially from a central axis of the drive coupler, the drive coupler is telescoped at least partially within the drive hub such that the first lobe that engages with a portion of the cross-sectional shape.