Surgical Stapler Motor Control via Drive Acceleration Feedback
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Solution Overview
Problem
Current surgical stapling instruments face challenges in efficiently deploying staples and cutting tissue with precise control, particularly in minimally invasive procedures, where the integration of sensors for feedback is limited and the power management system is not optimized for efficient operation.
Innovation Solution
A surgical stapling system with an interchangeable shaft assembly and end effector that includes a staple cartridge and anvil, where the cartridge is designed with six longitudinal rows of staples, and a firing mechanism that uses a sled and camming surfaces to eject staples and a knife for cutting, along with a power system that includes a segmented circuit for efficient energy distribution and a microcontroller for sensor integration and motor control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are integrated for feedback control, then measurement precision and control accuracy are improved, but device complexity increases
Solution Approach 1:
The surgical instrument is divided into modular components with sensors strategically placed at specific locations (jaw closure, staple formation, cutting phases). Each sensor module is independently integrated into specific functional areas, allowing precise measurement without requiring complete sensor coverage throughout the entire device, thus balancing measurement precision with manageable device complexity
Solution Approach 2:
The microcontroller is designed to process signals from multiple different sensor types (position sensors, force sensors, temperature sensors) using a unified control algorithm. This multi-functional approach allows a single control unit to handle diverse sensor inputs, improving measurement precision across multiple parameters while avoiding the need for separate dedicated control circuits for each sensor type
2Manufacturing precision
If motor speed and torque are dynamically adjusted based on feedback, then manufacturing precision of staple formation is improved, but use of energy increases
Solution Approach 1:
The motor control system dynamically adjusts speed and torque based on real-time feedback from sensors during the stapling process. The microcontroller receives position and force sensor data, then continuously modifies motor parameters to optimize staple formation precision while avoiding excessive energy consumption. This dynamic adaptation allows the system to use higher power only when needed for precise staple deformation rather than maintaining high power throughout the entire operation
Solution Approach 2:
The motor operation is divided into distinct periodic phases corresponding to different surgical actions (jaw closure, staple formation, cutting, resetting). During each phase, the motor parameters are optimized for that specific function - for example, using high torque only during the brief staple formation moment rather than continuously, and lower power during transit and positioning phases, thereby reducing overall energy consumption while maintaining precision when required
Data Source
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AI summary
A surgical stapler. The surgical stapler includes a drive system, an electric motor, a battery and a control system. The drive system includes a movable drive member. The electric motor is mechanically coupled to the drive system. The battery is electrically couplable to the electric motor. The control system is electrically connected to the electric motor and includes an accelerometer. The control system is configured to control a force applied to the drive system based on an acceleration of the movable drive member.