Methods and systems for detecting staple cartridge misfire or failure

• US 10,213,202 B2
• Filed: 06/28/2016
• Issued: 02/26/2019
• Est. Priority Date: 02/15/2011
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Flanagan, Patrick, Weir, David
• Primary Examiner(s): Smith, Scott A.
• Application Number:
  US15/194,771
• Publication Number:
  US 20160374676A1
• Time in Patent Office: 973 Days
• Field of Search: 227 19, 2271751, 2271752, 2271761, 2271781, 2271801, 606139, 606153, 606219
• CPC Class Codes: A61B 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/072 for applying a row of staples in a single action , e.g. the staples being applied simultaneously
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 17/115 Staplers for performing anastomosis in a single operation
• CPC Class Codes: A61B 2017/00017 Electrical control of surgical instruments
• CPC Class Codes: A61B 2017/00022 Sensing or detecting at the treatment site
• CPC Class Codes: A61B 2017/00115 with audible or visual output with imaging means A61B90/37, A61B34/20
• CPC Class Codes: A61B 2017/07214 Stapler heads
• CPC Class Codes: A61B 2017/07271 characterised by its cartridge
• CPC Class Codes: A61B 2090/064 for measuring force, pressure or mechanical tension
• CPC Class Codes: A61B 2090/0811 for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument
• CPC Class Codes: A61B 34/30 Surgical robots

Abstract

A method of controlling a surgical stapler system includes transmitting an actuation force to a staple cartridge to actuate a staple firing procedure, the staple cartridge being removably received by a portion of an end effector of a surgical instrument, measuring the transmitted actuation force, and controlling continued transmission of the actuation force based on a comparison of the measured actuation force to a range defined from a minimum threshold actuation force to a maximum threshold actuation force.

Claims

1. A method of controlling a surgical stapler system, comprising:

in response to input at a drive system, transmitting an actuation force to actuate a surgical instrument end effector to perform a stapling procedure, the surgical instrucment end effector comprising a removable staple cartridge;

measuring the transmitted actuation force; and

controlling continued transmission of the actuation force to the end effector based on a comparison of the measured actuation force to a range defined from a minimum threshold actuation force to a maximum threshold actuation force.

2. The method of claim 1, wherein controlling the continued transmission of the actuation force comprises:

stopping transmission of the actuation force if the measured actuation force is outside the defined range, or

continuing transmission of the actuation force if the measured actuation force is within the defined range.

3. The method of claim 2, wherein the actuation force is chosen from a force to actuate the surgical instrument end effector to perform a clamping function or a force to actuate the surgical instrument end effector to perform a staple firing function.

4. The method of claim 1, wherein transmitting the actuation force to actuate the surgical instrument end effector causes a clamping movement of the surgical instrument end effector.

5. The method of claim 1, further comprising:

indicating on a user interface a stapling procedure failure if the measured actuation force is outside the defined range.

6. The method of claim 5, wherein an indication of stapling procedure failure is indicated on the user interface as a percentile range based on the comparison of the measured actuation force to the defined range.

7. The method of claim 1, wherein transmitting the actuation force to actuate the surgical instrument end effector comprises moving one of a surgical blade of the surgical instrument end effector or deploying a staple deployment element of the staple cartridge.

8. The method of claim 7, further comprising:

stopping movement of the surgical blade of the surgical instrument end effector if the measured actuation force is outside the defined range.

9. The method of claim 7, further comprising:

stopping deployment of the staple deployment element of the staple cartridge if the measured actuation force is outside the defined range.

10. The method of claim 1, wherein controlling the continued transmission of the actuation force comprises continuing transmission of the actuation force to actuate a staple deployment element of the staple cartridge to deploy one or more staples in the staple cartridge if the measured actuation force is within the defined range.

11. The method of claim 1, wherein controlling the continued transmission of the actuation force comprises continuing transmission of the actuation force to actuate the surgical instrument end effector to perform a clamping function if the measured actuation force is within the defined range.

12. The method of claim 1, further comprising:

indicating on a user interface jamming of a staple in the staple cartridge if the measured actuation force is greater than the maximum threshold actuation force.

13. The method of claim 1, further comprising:

outputting an indication on a user interface of a status of the stapling procedure, wherein the status indicates a staple firing failure of the staple cartridge and/or clamping failure of jaws of the surgical instrument end effector.

14. The method of claim 13, wherein:

outputting the indication on the user interface comprises outputting an indication of failure of the stapling procedure in response to the measured transmitted actuation force being outside the defined range.

15. The method of claim 1, wherein the drive system comprises a motor and measuring the transmitted actuation force comprises measuring a drive parameter of the motor.

16. The method of claim 1, wherein:

the drive system comprises an actuator operably coupled to actuate the surgical instrument end effector; and

measuring the transmitted actuation force comprises detecting a displacement, velocity, and/or position of the actuator during the stapling procedure.

17. The method of claim 16, further comprising:

outputting an indication of staple firing failure on a user interface in response to a detected displacement, velocity, and/or position of the actuator being outside defined ranges for the detected displacement, velocity, and position of the actuator; and

terminating a firing sequence of the staple cartridge in response to the detected displacement, velocity, and/or position of the actuator being outside the defined ranges.

18. The method of claim 1, wherein transmitting the actuation force to actuate the surgical instrument end effector causes actuation of a staple deployment element of the staple cartridge.

19. The method of claim 18, further comprising:

prior to transmitting the actuation force to cause actuation of the staple deployment element, transmitting a clamping actuation force to actuate the surgical instrument end effector to exert a clamping force; and

maintaining the clamping force of the surgical instrument end effector while stopping transmission of the actuation force to cause actuation of the staple deployment element of the staple cartridge if the measured actuation force is outside the defined range.