Surgical Adapter Gear Assembly for Reliable Multi-Unit Connection
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Solution Overview
Problem
Existing adapter assemblies for electromechanical surgical devices face challenges in providing a robust and reliable mechanical and electrical connection, which is crucial for consistent performance but often complex and difficult to achieve.
Innovation Solution
The adapter assembly includes a gear assembly system with multiple shafts and gears that allow for rotational motion to be converted into longitudinal movement, enabling secure connections between surgical instruments and loading units, with features like support plates and apertures for precise alignment and support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex adapter assembly is used to interconnect surgical devices with multiple loading units, then the ability to establish mechanical and electrical connections is improved, but the device complexity increases
Solution Approach 1:
The adapter assembly is designed with a universal interface that can connect to multiple different loading units (single-use and reusable) through a standardized coupling mechanism. The gear assembly system provides multi-functional capability by enabling both mechanical drive transmission and electrical connection establishment through the same structural components, allowing one adapter to serve multiple loading unit types without requiring separate specialized adapters for each.
Solution Approach 2:
The adapter assembly is divided into distinct functional segments: a coupling mechanism for mechanical attachment, a gear assembly system for drive transmission, and an electrical connection system for signal and power transfer. This segmentation allows each component to be optimized independently while maintaining overall system versatility, reducing the complexity burden by organizing functions into modular, manageable sections rather than a monolithic complex structure.
2Reliability
If a robust mechanical connection system is implemented, then the reliability of the connection is improved, but the ease of operation decreases
Solution Approach 1:
The adapter assembly incorporates pre-configured alignment features and self-latching mechanisms that automatically engage when the adapter is attached to a loading unit. The gear assembly is pre-positioned to mesh with the drive shaft, and electrical contacts are pre-aligned to establish connection upon mechanical attachment. This preliminary configuration ensures that a simple attachment motion automatically achieves both robust mechanical connection and reliable electrical connection without requiring separate manual steps, thereby maintaining ease of operation while ensuring connection reliability.
Solution Approach 2:
The coupling mechanism acts as an intermediary between the simple attachment motion and the complex connection requirements. It translates a simple push-or-screw motion into the coordinated activation of mechanical drive transmission and electrical contact engagement. This intermediary mechanism mediates between the user's simple operation and the system's requirement for reliable multi-functional connection, ensuring both robustness and ease of use.
3Manufacturing precision
If multiple gear assemblies are used to convert rotational motion to longitudinal movement, then the precision of motion conversion is improved, but the device complexity increases
Solution Approach 1:
Multiple gear assemblies are merged into a single integrated drive transmission system where gears are co-axially arranged and share common mounting structures. The first gear assembly converts rotational motion from the first drive shaft to longitudinal movement of the first pusher, while the second gear assembly simultaneously converts rotational motion from the second drive shaft to longitudinal movement of the second pusher. By merging these gear assemblies into a unified structure with shared supports and alignment features, the precision of motion conversion is maintained while the overall complexity is reduced compared to having separate, independent gear systems.
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
This solution provides a robust and reliable mechanical and electrical connection, ensuring consistent performance and ease of use by converting rotational motion into precise longitudinal movement, addressing the complexity and reliability issues in existing systems.
Implementation Method 1
The first proximal shaft includes a first gear assembly. The second proximal shaft defines a longitudinal axis and includes a second gear assembly. The first distal shaft is disposed along the longitudinal axis and includes a third gear assembly. The first gear assembly is mechanically engaged with the third gear assembly. Rotation of the first gear assembly causes rotation of the third gear assembly.
Data Source
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AI summary
An adapter assembly for operably connecting an end effector to a surgical instrument. The adapter assembly includes a first proximal shaft, a second proximal shaft, a first distal shaft, and a second distal shaft. The first proximal shaft includes a first gear assembly. The second proximal shaft defines a longitudinal axis and includes a second gear assembly. The first distal shaft is disposed along the longitudinal axis and includes a third gear assembly. The first gear assembly is mechanically engaged with the third gear assembly. The second distal shaft includes a fourth gear assembly. The second gear assembly is mechanically engaged with the fourth gear assembly. A distal portion of the second distal shaft is disposed at least partially within an internal cavity of the third gear assembly.