Powered Stapler Handle With Manual Retraction for Power Loss
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Solution Overview
Problem
Powered surgical stapling devices face difficulties when power is lost or components are damaged, leading to the device being clamped on tissue and preventing removal from a patient.
Innovation Solution
A powered handle assembly with a manual retraction mechanism, featuring a gear casing, motor assembly, toothed rack, clutch assembly, and retraction knob, allowing for manual operation to disengage the drive assembly when power is lost or components are damaged.
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 are damaged
Solution Approach 1:
The drive gear is designed to be movable between a first position (engaged with the toothed rack for powered operation) and a second position (disengaged from the toothed rack for manual retraction). This dynamic reconfiguration allows the system to switch between powered and manual modes, ensuring the device can be removed even when power is lost or components are damaged.
Solution Approach 2:
The clutch assembly acts as an intermediary mechanism between the motor assembly and the toothed rack. It includes a movable gear that can be positioned to either engage the toothed rack (enabling powered operation) or disengage from it (enabling manual retraction). This intermediary component facilitates the transition between powered and manual modes, resolving the contradiction between ease of operation and reliability.
2Productivity
If a motor assembly is used to actuate the stapling device, then productivity is improved, but device complexity increases due to additional components
Solution Approach 1:
The movable gear in the clutch assembly serves multiple functions: it engages the toothed rack during powered operation to transmit motor torque, and it can be disengaged to allow manual retraction of the drive assembly. This multi-functionality reduces the need for separate mechanisms for powered and manual operation, thereby managing device complexity while maintaining productivity.
Solution Approach 2:
The clutch assembly merges the powered actuation mechanism and the manual retraction mechanism into a single integrated system. The movable gear combines the functions of power transmission and disengagement control, reducing the overall number of components needed while maintaining both powered operation capability and manual retraction capability.
3Ease of operation
If the drive assembly is designed for powered operation only, then ease of operation is improved, but ease of repair deteriorates when components are damaged
Solution Approach 1:
The manual retraction mechanism extracts the capability to retract the drive assembly from the powered motor system. By providing a separate manual operation path through the clutch assembly and movable gear, the system can be removed even when the motor assembly or other powered components are damaged, improving ease of repair and device removal.
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 the surgical device to be manually retracted, ensuring it can be safely removed from a patient even in power loss or component failure scenarios.
Implementation Method 1
The gear teeth of the first gear engage with the gear teeth of the second gear such that rotation of the first gear causes rotation of the second gear
Implementation Method 2
The toothed rack is received within the longitudinal channel of the gear casing and is movable through the casing cavity between retracted and advanced positions. The drive gear is engaged with the toothed rack in the first drive gear position
Data Source
AI summary
A powered handle assembly includes a motor assembly, a toothed rack, a drive gear, a clutch assembly, a manual retraction gear, and a retraction knob. The motor assembly is coupled to the drive gear, and the drive gear is movable from a first position engaged with the rack to a second position disengaged from the rack. The clutch assembly includes a lower gear and an upper gear that is coupled to the retraction knob and movable to a position engaged with the lower gear. The lower gear is engaged with the manual retraction gear and the manual retraction gear is engaged with the rack such that rotation of the retraction knob causes longitudinal movement of the rack. The handle assembly allows for manual retraction of a drive assembly of the surgical device when power is lost, or components are damaged.