Torque-Limiting Surgical Driver for Bone Layer Detection
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Solution Overview
Problem
Existing surgical drivers lack the ability to accurately detect transitions through different bone layers and prevent damage to surrounding tissue by determining when a drill bit has penetrated through the entirety of a bone cross-section.
Innovation Solution
A torque-limiting surgical driver that monitors the torque applied to the drill bit and stops or reduces its rotation when specific torque criteria are met, allowing for differentiation between various bone densities and preventing the drill bit from penetrating beyond the bone cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If powered surgical instruments are used to drill into bone, then drilling speed and efficiency are improved, but the ability to detect transitions through different bone layers and prevent tissue damage deteriorates
Solution Approach 1:
The surgical drilling system incorporates real-time feedback mechanisms through torque sensors that continuously monitor drilling resistance. When the torque exceeds predetermined thresholds indicating transition between bone layers or cortical bone penetration, the system provides immediate feedback to the surgeon via visual or haptic signals, enabling timely intervention to prevent tissue damage while maintaining high drilling speeds.
Solution Approach 2:
The patent replaces manual mechanical detection methods with electronic sensing systems. Torque sensors and motor control systems substitute for the surgeon's manual feel, providing objective, quantifiable measurements of drilling resistance that enable reliable detection of bone layer transitions even at high automated drilling speeds.
2Productivity
If high-speed powered drilling is used, then surgical efficiency is improved, but the risk of drill bit plunging through bone and damaging surrounding tissue increases
Solution Approach 1:
The system implements preliminary anti-action by establishing predetermined torque thresholds before drilling begins. These thresholds represent the maximum acceptable torque that indicates approaching critical bone layer transitions. By setting these limits in advance and monitoring continuously, the system prepares preventive measures that can be activated before damage occurs, allowing high-speed drilling with reduced plunging risk.
Solution Approach 2:
Real-time torque monitoring provides continuous feedback during drilling operations. When torque values approach predetermined thresholds indicating imminent bone layer transition or cortical bone penetration, the system immediately alerts the surgeon through visual displays or haptic feedback on the drill handle, enabling corrective action before tissue damage occurs while maintaining high drilling efficiency.
3Reliability
If torque monitoring and limiting controls are added to surgical drivers, then tissue damage prevention is improved, but device complexity increases
Solution Approach 1:
The surgical drilling system integrates multiple functions into a single unified platform. The motor control system serves both to drive the drill bit at high speeds and to monitor torque through the same motor current measurements. The control electronics that manage drilling speed also process torque data for tissue detection, eliminating the need for separate dedicated components and reducing overall system complexity despite added functionality.
Solution Approach 2:
The motor's electrical characteristics are utilized to provide torque information without requiring separate sensing mechanisms. By monitoring motor current and power consumption, the system derives torque data that reflects drilling resistance, allowing the motor itself to serve as both the driving force and the sensing element, thereby reducing device complexity while maintaining reliable tissue damage prevention capabilities.
Data Source
AI summary
Various torque-limiting surgical driver devices, systems, and methods are disclosed. The surgical driver can include a body, a motor that is configured to rotate a drill bit engaged with the surgical driver, and a processor configured to control operation of the surgical driver. The surgical driver can have torque-limiting functionality, such as by monitoring the amount of torque applied to a drill bit and reducing or stopping rotation of the drill bit when certain torque-limiting criteria are met.