Programmable Swaging Press Control for Needle-Suture Attachment
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Solution Overview
Problem
Existing swaging presses face limitations in precision, control, and efficiency when attaching surgical needles to sutures, particularly in cardiovascular surgery, due to difficulties in setup adjustments, force measurement, real-time feedback, and precise control of swaging processes, leading to issues like needle cracking and loss of attachment over time.
Innovation Solution
A programmable swaging press equipped with a bottom and top swaging die, load cell for load data recording, servomotor for precise location control, and a microprocessor-based control system that provides real-time feedback and programmable swage programs for optimized displacement and load management, enabling precise control of the swaging process and assessment of needle-suture attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual or semi-automated swaging procedures are used, then device complexity is reduced, but manufacturing precision and reliability of needle-suture attachment deteriorate
Solution Approach 1:
The patent replaces manual mechanical swaging operations with an automated motor-driven swaging press that uses electrical motors to control the swaging dies. This substitution of mechanical manual operations with motorized automation enables precise control of swaging force and displacement through electronic control systems, thereby improving manufacturing precision while managing device complexity through systematic automation.
Solution Approach 2:
The patent incorporates feedback mechanisms including load cells to measure swaging force and displacement sensors to monitor die movement. This real-time feedback allows the control system to adjust swaging parameters dynamically, ensuring consistent needle-suture attachment precision. The feedback loop enables closed-loop control that maintains high manufacturing precision by continuously monitoring and adjusting the swaging process.
2Device complexity
If simple mechanical linkages or pneumatic systems are used, then device complexity is reduced, but control precision and real-time feedback capability deteriorate
Solution Approach 1:
The patent replaces simple mechanical linkages and pneumatic systems with motor-driven actuation systems controlled by microprocessors. This substitution enables digital control of swaging parameters and integration of electronic sensors for precise measurement. The motorized system allows for programmable control sequences and real-time monitoring, achieving high measurement precision through electronic sensing and digital processing while managing complexity through integrated control architecture.
Solution Approach 2:
The patent implements comprehensive feedback systems using load cells for force measurement and displacement sensors for position monitoring. These sensors provide real-time data to the microprocessor control system, enabling precise measurement and control of swaging parameters. The feedback mechanism allows dynamic adjustment of swaging force and displacement, ensuring measurement precision through continuous monitoring and electronic regulation.
3Strength
If multiple percussive strikes are applied during swaging, then attachment strength is improved, but risk of needle cracking increases
Solution Approach 1:
The patent employs periodic percussive strikes during the swaging process, where the swaging die applies a series of controlled impact loads to the needle-suture assembly. This periodic action allows the material to work-harden progressively, improving attachment strength through controlled deformation. The intermittent nature of the strikes prevents excessive heat buildup and allows stress redistribution, reducing the risk of needle cracking while achieving strong attachment.
Solution Approach 2:
The patent uses dynamic control of swaging force through motor-driven actuation, allowing the system to adjust strike intensity and frequency in real-time. The motorized system can modulate the force of each percussive strike and control the timing between strikes, optimizing the balance between achieving sufficient attachment strength and preventing needle cracking. This dynamic control enables adaptive swaging that responds to real-time feedback from load cells and displacement sensors.
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
The programmable swaging press enhances the reliability and efficiency of attaching surgical needles by ensuring precise control over displacement and load, reducing the risk of needle cracking and improving the durability of the needle-suture attachment, thereby improving the quality of armed surgical needles for delicate surgical procedures.
Implementation Method 1
A load cell on the bottom die records load data
Implementation Method 2
A servomotor on the top die records location data corresponding to the location of the top die on the swaging axis
Implementation Method 3
a swage die impinges upon the outer surface of the needle barrel, thereby compressing a portion of the bore onto the suture. The compressed portion of the axial bore grasps the suture by mechanical interference and by surface friction.
Implementation Method 4
The compressed portion of the axial bore grasps the suture by mechanical interference and by surface friction
Data Source
Figure 1~2
Figure 3~4
Figure 5A
AI summary
A swaging system for attaching surgical needles to sutures and testing the attachment strength includes a frame, a bottom swaging die mounted on the frame, and a top swaging die mounted on the frame and being moveable up and down along a swaging axis that is aligned with the bottom swaging die. The bottom swaging die includes a hinge mechanism with a bottom plate mounted to the frame and a top plate overlying the bottom plate. The top and bottom plates are pivotally connected for enabling the top plate to pivot relative to the bottom plate. The bottom swaging die includes a swaging tool that extends toward the top swaging die along the swaging axis, and a load cell disposed between the top and bottom plates for monitoring load. The system includes a control system having one or more pull test programs stored therein for conducting pull tests on armed surgical needles to determine if the armed surgical needles are acceptable or unacceptable.