Surgical Robot Motor Current Monitoring for Drivetrain Fault Detection
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Solution Overview
Problem
Current surgical instruments face challenges in efficiently detecting and responding to drivetrain failures during surgical procedures, which can lead to suboptimal performance or safety issues.
Innovation Solution
The development of a surgical instrument system that includes a drivetrain failure detection module and a motor control circuit capable of selectively engaging different drivetrains, allowing for continued operation despite acute failures and ensuring safety by preventing further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional surgical instruments are used without fault detection, then the device complexity is low, but the reliability deteriorates due to inability to detect drivetrain failures
Solution Approach 1:
The system performs preliminary monitoring of motor current draw during operation to detect fault states before they lead to complete drivetrain failure. The control circuit continuously compares actual current against expected current profiles to identify deviations indicating potential failures.
Solution Approach 2:
The system implements feedback by monitoring motor current draw and using this information to detect fault states. The control circuit receives current feedback from the motor driver and adjusts operation based on detected fault conditions, enabling continued safe operation or appropriate shutdown.
2Reliability
If the surgical instrument shuts down completely upon detecting a fault, then safety is improved, but productivity deteriorates due to interruption of surgical procedure
Solution Approach 1:
The system dynamically adjusts its response based on the detected fault state. Instead of a fixed shutdown response, the control circuit can modify motor control parameters, reduce power output, or switch to alternative drivetrains depending on the nature and severity of the detected fault, allowing continued operation in modified modes.
Solution Approach 2:
The system changes operational parameters when fault states are detected. The control circuit modifies motor current limits, speed parameters, or torque settings to accommodate the fault condition while maintaining safe and effective surgical function. This allows the instrument to adapt its performance characteristics based on detected issues.
3Productivity
If the surgical instrument continues operating without fault detection, then productivity is maintained, but harmful factors increase due to potential additional tissue damage
Solution Approach 1:
The control circuit continuously monitors motor current draw and uses this feedback to detect fault states that could lead to harmful operation. When deviations from expected current profiles are detected, the system adjusts its operation to prevent additional tissue damage while maintaining procedural continuity where safe.
Solution Approach 2:
The system performs self-diagnosis by monitoring its own motor current characteristics. The control circuit identifies fault states through self-monitoring of operational parameters and automatically adjusts its operation to prevent harmful effects, enabling the instrument to protect itself and the patient without external intervention.
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 instrument to maintain functionality and safety during drivetrain failures by detecting issues and adjusting operations to complete procedures without causing additional damage.
Implementation Method 1
the motor control circuit to detect the fault state based on the motor current draw
Data Source
AI summary
A surgical robotic system includes a housing, wherein the housing includes a rotary drive; a motor that applies a rotary motion to the rotary drive; a surgical tool that releasably attaches to the housing, the surgical tool including: an end effector; a rotary interface that releasably couples to the rotary drive; a firing assembly; a lockout member movable from a locked state to an unlocked state by a sled; and a control circuit communicably coupled to the motor, wherein the control circuit is configured to: activate the motor to effect the motion of the firing assembly; monitor a current draw of the motor during the motion of the firing assembly; detect a fault state in the motion of the firing assembly based on the current draw of the motor; stop the motor based on the detection of the fault state; and alert a user regarding the fault state.