Powered Stapler Premature Ejection Detection
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Solution Overview
Problem
Conventional circular staplers face issues with partially ejected staples, leading to malformed staples due to premature staple ejection before the stapling process.
Innovation Solution
A powered circular stapler with a handle assembly, adapter assembly, and reload, featuring a distance sensor and controller to determine if staples have been previously ejected by measuring the travel distance of the transmission assembly to a hard stop, thereby preventing further use of the reload if staples are detected as partially ejected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transmission assembly is used to eject staples during the stapling process, then the stapling function is achieved, but staples may be partially ejected and malformed due to premature ejection before the intended stapling sequence
Solution Approach 1:
The system performs preliminary detection of staple position before the stapling sequence begins. The controller checks whether staples are already partially ejected by monitoring the transmission assembly position or using sensors, and prevents activation of the stapling sequence if premature ejection is detected, thereby ensuring staple formation quality without requiring complex real-time intervention during ejection
Solution Approach 2:
The system implements feedback control by continuously monitoring the position of the transmission assembly and staple cartridge using sensors (e.g., optical sensors, encoders). This feedback allows the controller to detect premature staple ejection and adjust or prevent the stapling sequence accordingly, ensuring reliable staple formation while maintaining controlled system operation
2Ease of operation
If the drive shafts push staples during the clamping sequence in preparation for stapling, then the staples are positioned for ejection, but this may result in malformed staples due to premature ejection
Solution Approach 1:
The system performs preliminary positioning of staples during the clamping sequence, but includes a verification step before the ejection sequence begins. The controller checks whether staples are properly positioned and not prematurely ejected by monitoring transmission assembly position and staple cartridge status, ensuring both ease of positioning and precision of staple geometry
Solution Approach 2:
The system replaces purely mechanical staple positioning with a controlled electromechanical system. The transmission assembly is actuated by a motor under controller supervision, allowing precise control of staple positioning during clamping and preventing premature ejection through electronic control and sensor feedback, thereby maintaining both ease of operation and manufacturing precision
3Productivity
If the reload is reused after partial staple ejection, then resource utilization is improved, but malformed staples are produced compromising surgical integrity
Solution Approach 1:
The system implements feedback control by continuously monitoring the position of the transmission assembly and staple cartridge using sensors (e.g., optical sensors, encoders). This feedback allows the controller to detect premature staple ejection and adjust or prevent the stapling sequence accordingly, ensuring reliable staple formation while maintaining controlled system operation
Solution Approach 2:
The system applies preliminary anti-action by detecting the condition of previously ejected staples before allowing reload reuse. The controller checks staple position and transmission assembly status, and if partial ejection is detected, prevents further use of the reload by blocking the ejection sequence or alerting the user, thereby preventing malformed staples while allowing resource utilization when conditions are appropriate
Data Source
AI summary
A surgical device includes a power source, a motor coupled to the power source, and a transmission assembly movable by the motor. The device also includes a reload coupled to the transmission assembly. The reload includes a plurality of staples ejectable by the transmission assembly. The device further includes a distance sensor configured to monitor operation of the transmission assembly and output distance data. The device additionally includes a controller configured to operate the motor to move the transmission assembly proximally from a distal position until a hard stop is reached, and determine whether the plurality of staples have been previously ejected based on the distance data.