Surgical Impactor Chuck Assembly for Six-DOF Instrument Stability
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Solution Overview
Problem
Existing chuck designs for powered surgical impactors allow significant free play between the chuck and surgical instruments, leading to limited axial and radial stability, increased difficulty in surgical operations, prolonged surgery duration, and potential wear on instruments due to varied or reduced forces.
Innovation Solution
A chuck system that constrains surgical instruments in six degrees of freedom using cylindrical surfaces, faces, and lock projections to precisely maintain alignment, reducing movement and variability of impaction forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional chuck designs are used for powered surgical impactors, then the device is simpler to manufacture, but significant free play occurs between the chuck and surgical instruments leading to limited axial and radial stability
Solution Approach 1:
The chuck system is divided into three separate bodies (first body, second body, third body) that can be manufactured independently and then assembled. Each body contains specific constraint features: the first body has a cylindrical surface for radial constraint, the second body has a face for axial constraint, and the third body has a lock projection for positioning. This segmentation allows complex stability features to be achieved through simpler individual components.
Solution Approach 2:
The three bodies are nested within each other in a concentric arrangement, with the first body inserted into the second body, and the third body inserted into the second body. This nested configuration allows the multiple constraint surfaces to be integrated in a compact structure while maintaining the complexity needed for six-degree-of-freedom constraint.
2Ease of operation
If existing chuck designs are used, then the device complexity is lower, but surgical operations become more difficult and surgery duration increases due to free play
Solution Approach 1:
The chuck system pre-constrains the surgical instrument in six degrees of freedom before the surgical operation begins. The cylindrical surfaces, faces, and lock projections are designed to automatically engage and eliminate free play when the instrument is inserted, providing immediate stability without requiring additional adjustment steps during surgery.
Solution Approach 2:
The chuck system automatically maintains precise alignment and constraint of the surgical instrument through its geometric features (cylindrical surfaces for radial constraint, faces for axial constraint, lock projection for positioning). Once assembled and the instrument is inserted, the system self-maintains the constrained position without requiring continuous surgeon intervention or adjustment.
3Reliability
If traditional chuck designs are used, then manufacturing is simpler, but instrument wear increases due to varied or reduced forces
Solution Approach 1:
The chuck system changes the geometric parameters of the constraint surfaces to achieve precise six-degree-of-freedom constraint. The cylindrical surfaces provide radial constraint through specific diameter measurements, the faces provide axial constraint through parallel surface geometry, and the lock projection provides angular positioning. These parameter-controlled geometric features ensure consistent force transfer.
4Manufacturing precision
If existing chuck designs are used, then the device is simpler to manufacture, but axial impaction force consistency decreases leading to reduced surgical precision
Solution Approach 1:
The chuck system applies different local constraint qualities at different locations: the cylindrical surfaces provide radial constraint quality, the faces provide axial constraint quality, and the lock projection provides angular positioning quality. Each local feature is optimized for its specific constraint function, achieving high overall precision through differentiated local characteristics.
Data Source
AI summary
A chuck for a powered surgical impactor can include a first body insertable into the powered surgical impactor and defining a first bit bore, a second body adapted to receive the first body; and a third body receivable at least partially within the second body and defining a second bit bore. The third body can define a lock projection extending radially inward into the second bit bore; and the third body and the second body can be adapted to rotate relative to the first body to move the lock projection between an unlocked position, in which the lock projection is located to allow insertion of a surgical instrument into the chuck, and an unlocked position, in which the lock projection is located to prevent removal of the surgical instrument from the chuck.