Powered Surgical Stapler End Effector Identification
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Solution Overview
Problem
Current surgical staplers require significant manual force for clamping and deploying surgical fasteners, leading to user fatigue, and lack advanced sensors for feedback-controlled adjustments during articulation and stapling processes.
Innovation Solution
A powered surgical instrument with a sensor tube and microcontroller system that distinguishes between articulating and non-articulating loading units, allowing for precise control of articulation and stapling through variable loading unit sensors and non-linear speed controls, reducing manual effort and enhancing user control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual force is used to clamp tissue and deploy surgical fasteners, then the surgical instrument can perform basic stapling functions, but user fatigue occurs due to repeated use requiring 10-60 pounds of manual force
Solution Approach 1:
The patent replaces the manual mechanical clamping system with a motorized actuation system. A motor (200) drives a firing rod (220) that mechanically actuates the end effector (160) to clamp and fire staples, eliminating the need for the user to manually apply 10-60 pounds of force repeatedly. The motorized system converts electrical energy to mechanical work, substituting human physical effort with automated mechanical actuation.
2Ease of operation
If gas powered pneumatic staplers are used to implant surgical fasteners, then the stapling function is achieved, but user control is limited as the trigger mechanism only releases pressurized gas without fine adjustment capability
Solution Approach 1:
The patent implements a dynamic control system where a motor (200) can be precisely controlled in terms of speed, torque, and direction. The motor controller (414) receives signals from the user interface (240) and adjusts motor parameters in real-time, allowing fine control over the clamping force, firing speed, and articulation angle. This dynamic control replaces the static on/off trigger mechanism of pneumatic staplers.
Solution Approach 2:
The patent incorporates sensors (310, 320, 330, 340) that detect parameters such as end effector position, articulation angle, and tissue clamping force. These sensors provide feedback signals to the controller (400), which automatically adjusts motor commands to maintain desired operating conditions. This closed-loop feedback control enables precise user control while compensating for variations in tissue properties and mechanical play.
3Extent of automation
If motor powered surgical staplers with single switch control are used, then automated actuation is achieved, but user control remains limited as only a single switch can be toggled to actuate the motor
Solution Approach 1:
The patent segments the control functions into multiple independent controls on the user interface (240). Instead of a single switch, the system provides separate controls for motor actuation, articulation, speed adjustment, and firing initiation. Each control can be independently adjusted, allowing the user to customize the operation parameters according to specific surgical requirements while maintaining automated motor actuation.
4Adaptability or versatility
If the body portion is designed to accommodate both articulating and non-articulating loading units, then device versatility is improved, but the mechanism complexity increases due to the need for articulation mechanisms
Solution Approach 1:
The patent designs the body portion (140) with a universal interface that can accommodate both articulating and non-articulating loading units (169). The articulation mechanism (210) is configured to be engaged or disengaged based on the type of loading unit inserted. When an articulating loading unit is detected, the articulation mechanism becomes active; when a non-articulating unit is inserted, the mechanism remains inactive. This universal design allows one instrument to perform multiple functions without requiring separate devices.
Solution Approach 2:
The system automatically detects the type of loading unit inserted and self-configures the articulation mechanism accordingly. Sensors (310, 320) detect mechanical features of the loading unit and automatically enable or disable articulation control functions without requiring manual intervention from the user. The controller (400) adapts its operation based on the detected loading unit type, reducing the complexity of manual configuration.
Data Source
AI summary
According to one aspect of the present disclosure, a surgical instrument is disclosed. The instrument includes a handle portion, a body portion extending distally from the handle portion and defining a first longitudinal axis and a loading unit. The loading unit includes a tool assembly, the loading adapted to be coupled to the body portion. The instrument also includes a sensor tube movably positioned within the body portion, the sensor tube adapted to engage the loading unit and a load switch coupled to a microcontroller. The load switch is adapted to be actuated by the sensor tube when the sensor tube is engaged by the loading unit being inserted into the body portion.